JP5008824B2 - Cushion material - Google Patents

Description

The present invention relates to a cushion material .

  Conventionally, cushion spring materials such as sofas and mattresses are often used.

  As the cushion spring material, a cushion coil spring sheet in which a coil spring is contained in a continuous bag in a row and arranged in a sheet shape, or a columnar elastic body is disposed in the coil spring. Alternatively, there are those in which columnar bodies made of polyurethane foam are arranged at predetermined intervals, and further, those made of cushioning material such as cotton, felt, or flat foam.

However, the conventional spring material for cushion has a problem of large sag (compression set) when used for a long time. Furthermore, the above-described pocket coil spring sheet and those in which a columnar elastic body is disposed in the coil spring have a problem that the structure is complicated and the cost is increased.
Japanese Utility Model Publication No. 7-20906 JP 2000-83767 A Japanese Patent Laid-Open No. 2004-113637

  The present invention has been made in view of the above points, and an object of the present invention is to provide a spring material and a cushion material which have a small sag when used for a long time and are inexpensive.

According to the first aspect of the present invention, a non-breathable support layer member and a breathable elastic layer member are disposed to face each other, and an outer surface excluding both end surfaces is constituted by a skin layer between the support layer member and the elastic layer member. Of the spring material in which air flow is generated from at least one of the end faces of the columnar elastic foam when the columnar elastic foam is pressed along the axial direction of the columnar elastic foam. A plurality of the spring members are arranged substantially parallel to each other and substantially perpendicular to the support layer member and the elastic layer member, and the adjacent spring members are in close contact with each other. contact surface is related to the cushion material, characterized in that there is a non-adhesive.

According to a second aspect of the present invention, in the first aspect , the plurality of spring members are accommodated in the opening of the frame member made of an elastic body having an opening at the center, and are arranged between the support layer member and the elastic layer member. It is characterized by that.

According to a third aspect of the present invention, in the first or second aspect , the plurality of spring members between the support layer member and the elastic layer member are bonded to the support layer member.

A fourth aspect of the present invention provides the spring material according to any one of the first to third aspects, wherein the spring material has a density of 0.10 to 0.16 g / cm ³ and a rebound resilience of a portion excluding the skin layer of 10 to 40%. The outer surface hardness of the skin layer is an Asuka F hardness of 55 to 85 degrees.

  It is known that the elastic foam has a reduced settling (compression set) as the density increases. In addition, the elastic foam having a skin layer on the outer surface is a portion formed by contact with a molding paper or a mold surface during foaming to inhibit foaming, and has a high density. The columnar elastic foam having a skin layer on the outer surface compresses and deforms in the direction of shrinking the skin layer when a pressure is applied in parallel with the skin layer having a high density. (Strain) can be obtained, and sag (compression set) can be suppressed as compared with compression deformation of an elastic foam having no skin layer.

As understood from this point , according to the cushioning material of the invention described in claim 1 , the spring material is composed of a columnar elastic foam whose outer surface excluding both end surfaces is constituted by a skin layer, and the columnar shape. Since the pressure is applied along the axial direction of the elastic foam, a compressive deformation force is applied along the skin layer in the vicinity of the outer surface where the skin layer is present during pressing. An effect of reducing (compression set) can be obtained. Moreover, since the columnar elastic foam constituting the spring material of the present invention is in a state in which the outer surface excluding both end faces is surrounded by a skin layer having a high density, when compressed in the axial direction, Since air flow through the skin layer is hindered and air escapes mainly from the end face of the columnar elastic foam, the air stays temporarily in the columnar elastic foam and has a resilience and resilience like an air spring. Demonstrates and can also reduce the drooping effect.

According to the cushion material of the first aspect of the present invention , the spring material has a configuration in which a plurality of columnar elastic foams whose outer surfaces excluding both end surfaces are constituted by skin layers are arranged substantially in parallel. Therefore, a plurality of cylindrical skin layers along the pressurizing direction are present substantially in parallel, and the spring material is constituted by one of the large columnar elastic foams whose outer surfaces excluding both end faces are constituted by the skin layers. Compared to the case, the number of cylindrical skin layers increases. Therefore, dripping (compression set) can be effectively suppressed even in the central portion.

According to the cushion material of the invention according to claim 1, the spring material according to claim 1 is arranged in a plurality substantially parallel, the skin layer of columnar elastic foam, sag of the spring member, i.e. It is possible to suppress the sag (compression set) of the cushion material. In addition, since a plurality of cylindrical skin layers along the pressing direction are present substantially in parallel, a spring material consisting of one large columnar elastic foam whose outer surface excluding both end surfaces is composed of skin layers is provided. The number of cylindrical skin layers is increased as compared with the case where it is used, and sag (compression set) can be effectively suppressed even at the center of the cushion material. Further, in the cushion material of the invention according to claim 3, a plurality of the spring materials according to claim 1 are substantially parallel to each other between the non-breathable support layer member and the breathable elastic layer member. Since the support layer member and the elastic layer member are arranged substantially perpendicular to each other, when the elastic layer member is pressurized by sitting or lying down when using the cushion material, the non-breathable support layer member The end surface on the support layer member side of the spring material is sealed. As a result, in the spring material, ventilation on the outer surface excluding the end surface on the elastic layer member side is hindered, and the elastic restoring force is improved by the action of the air spring, and the sag is more effectively prevented. It will be possible to suppress. Furthermore, the cushion material of the present invention has a simple structure and is less expensive than a pocket coil spring sheet or a material in which a columnar elastic body is disposed in a coil spring.

According to the cushion material of the invention described in claim 2, the support layer member and the elastic layer according to claim 1 , wherein the plurality of spring materials are accommodated in an opening of a frame member made of an elastic body having an opening in the center. By arranging between the members, it is possible to prevent the spring material from collapsing at the edge of the cushion material when a load is applied to the edge of the cushion material. However, it is possible to obtain a good cushioning property by properly elastically deforming the spring material.

According to the cushion material of the invention described in claim 3 , in claim 1 or 2 , the plurality of spring materials between the support layer member and the elastic layer member are bonded to the support layer member. When a load is applied on the cushion material and the plurality of spring materials are compressed, the plurality of spring materials do not move arbitrarily, and an elastic restoring force can be exhibited at a correct position. In addition, since the adjacent spring materials are not bonded to each other, a plurality of spring materials can be independently deformed. For example, a certain spring material is not loaded but is adjacent to a load. It is possible to prevent deformation due to the deformation of the spring material, and to improve the body pressure dispersibility of the cushion material.

According to the cushioning material of the invention described in claim 4 , in any one of claims 1 to 3 , the spring material has a density of 0.10 to 0.16 g / cm ³ and repulsion of a portion excluding the skin layer. The elasticity of 10 to 40% and the outer surface hardness of the skin layer is Asuka F hardness 55 to 85 degrees, so that a spring material made of a columnar elastic foam whose outer surface excluding both end surfaces is composed of a skin layer is cushioned. It is suitable for the material.

  Hereinafter, embodiments of the present invention will be described in detail. 1 is a perspective view of a first embodiment of the spring material of the present invention, FIG. 2 is a perspective view of a second embodiment of the spring material of the present invention, and FIG. 3 is a perspective view of a third embodiment of the spring material of the present invention. 4 is a cross-sectional view of an embodiment of the cushion material according to the present invention, FIG. 5 is an exploded perspective view showing a support layer member, a frame member, a spring material, and an elastic layer member of the cushion material, and FIG. FIG. 7 is a perspective view showing an embodiment of the sofa using the cushion material according to the present invention.

  The spring material 10 of the first embodiment shown in FIG. 1 is a columnar elastic foam whose outer surface 12 excluding both end faces 11 and 11 is composed of a skin layer 13 (hereinafter also referred to as a columnar elastic foam having a skin layer). The pressure is applied along the axial direction L of the columnar elastic foam 10A having the skin layer, and at least one of the end faces 11, 11 is the pressure side.

  The columnar elastic foam 10A having the skin layer is preferably made of polyurethane foam. As described in JP-A-2001-138342, the columnar elastic foam 10A having the skin layer is manufactured by continuously injecting a foaming raw material into a continuously formed cylindrical paper. By continuously foaming, a long rod-shaped elastic foam whose outer surface is made of a skin layer is formed, and then cut to a required length. In addition, the columnar elastic foam 10A having the skin layer may be a commercially available product, for example, a commercially available product as a packing material. it can.

The columnar elastic foam 10A having the skin layer has an appropriate density depending on the product in which the spring material 10 is used, but the cushion spring material has a density of 0.10 to 0.16 g / cm ³ (JIS). -In accordance with K-6400), the resilience (in accordance with JIS-K-6400-3: 2004) of the portion excluding the skin layer 13 (that is, the portion inside the skin layer 13) is 10 to 40%, particularly 20 to 30% is preferred. Further, the outer surface hardness of the skin layer 13 is preferably 55 to 85 (Asuka F hardness).

  The cross-sectional shape, cross-sectional area, and length between both end faces of the columnar elastic foam 10A having the skin layer are appropriately determined. For example, the cross-sectional shape includes a quadrangle shown in FIG. 1, a circle shown in FIG. 2, or an ellipse, triangle, and other polygons not shown.

In addition, the spring material of the present invention is configured by arranging a plurality of columnar elastic foams 10A having the skin layer substantially in parallel according to the arrangement space or load of the spring material. In particular, in a cushion material such as a sofa or a mattress, a spring material having a structure in which a plurality of columnar elastic foams 10A each having the skin layer are arranged substantially in parallel is preferable because the pressure area is wide.

A spring material 20 shown in FIG. 3 has a structure in which a plurality of spring materials 10 each made of a columnar elastic foam 10A having the skin layer are arranged substantially in parallel, and the spring material 10 of the columnar elastic foam 10A having the skin layer is formed. The pressure is applied along the axial direction L, and at least one of the both end faces 11, 11 is the pressure side. The spring material 20 is provided so that a plurality of the spring materials 10 made of the columnar elastic foam 10 </ b> A having the skin layer are in close contact with each other . In addition, when the spring material 10 which consists of 10 A of columnar elastic foams which have the said skin layer adjoins adjacently, the contact surface of adjacent is made non-adhesive. If the adjacent contact surfaces are not bonded, the spring material 10 made of the columnar elastic foam 10A having the skin layer can be compressed and deformed next to each other, so that the cushion material such as a sofa or a mattress can be used. When the spring is used, the load can be effectively absorbed. Further, in the spring material 20 having a structure in which a plurality of spring materials 10 made of the columnar elastic foam 10A having the skin layer are arranged substantially in parallel, the cross-sectional shape of the columnar elastic foam 10A having the skin layer is also provided. However, in the case where the neighbors are brought into close contact with each other, a polygon such as a triangle or a quadrangle can be easily brought into close contact with no gap.

  In addition, in the spring material 20 having a configuration in which a plurality of spring materials 10 made of the columnar elastic foam 10A having the skin layer are arranged substantially in parallel, the spring material made of the columnar elastic foam 10A having the skin layer. It is not necessary for all ten of the plurality to have the same physical property, and different physical properties may be combined. In particular, when the spring material 20 is used as a spring material for a cushion material such as a sofa or a mattress, the spring material 10 made of a plurality of columnar elastic foams 10A having the skin layer has different physical properties. By combining, the body pressure dispersibility of the cushion material can be improved.

  A cushion material 30 shown in FIG. 4 uses a plurality of the spring materials 10 as cushion material spring materials. As can be understood from FIGS. 5 and 6, the plurality of spring materials 10 and a support layer are used. A member 31, an elastic layer member 33, and a frame member 35, which are entirely covered with an exterior material 40 and used as a sofa seat as shown in FIG. 7, or are used as a mattress (not shown). It is used for other cushion products.

  A plurality of the spring members 10 are arranged substantially in parallel. The number of the spring members 10 is determined by the size of the cushion member 30 and the like. Further, the cross-sectional shape of the spring material 10 is not limited to a quadrangle as described above, but may be an appropriate shape such as a triangle or a circle. Further, as described above, the plurality of spring members 10 do not have to have the same physical properties, and those having different physical properties may be combined.

  The support layer member 31 serves as a support surface of the spring material 10 and corresponds to a bottom surface material or a back surface material. The support layer member 31 is made of a non-breathable material. The non-breathable material may be either highly rigid or elastic. For example, plates made of wood, plastic, metal, etc., elastic foam plates with a high ratio of closed cells (closed cell structure polyolefin foam, polystyrene foam, polyurethane foam, etc.), breathable Examples thereof include those in which the surface of the plate-like foam is made non-breathable by adhesion of a melt layer, an adhesive layer, or a film. The support layer member 31 is sized so that all of one end surfaces of the plurality of spring members 10 can be arranged.

  The elastic layer member 33 is disposed so as to cover the end surfaces of the plurality of spring members 10 on the side opposite to the support layer member 31, improves the cushioning property of the cushioning material 30 and ensures air permeability. Made of elastic material. The breathable elastic material is not particularly limited, but a polyurethane foam having a high proportion of open cells is suitable. The elastic layer member 33 has a size that can cover all end surfaces of the plurality of spring members 10 on the side opposite to the support layer member 31. In the illustrated example, the elastic layer member 33 has the same size as the planar size of the frame member 35. Become. Further, the thickness of the elastic layer member 33 is set to a thickness according to the cushioning property of the cushion material 30.

  The frame member 35 has an action of preventing the spring material 10 from falling outside at the edge of the cushion material 30 when the plurality of spring materials 10 are compressed, and a frame having an open center as shown in FIG. It is made of an elastic material so as not to impair the cushioning properties of the cushion material 30. Reference numeral 36 denotes a central opening. As the elastic material, a synthetic resin foam such as a polyurethane foam or a polyolefin foam is suitable. The frame member 35 has a size that can accommodate the plurality of spring members 10. In the illustrated example, the frame member 35 has the same height as the spring member 10. The elastic layer member 33 is the same.

  The frame member 35 is bonded to one side of the support layer member 31. A plurality of the spring members 10 are accommodated in the opening 36 of the frame member 35 so as to be substantially parallel to and substantially perpendicular to the support layer member 31 and the elastic layer member 33. The elastic layer member 33 is disposed on the side opposite to the support layer member 31 and the opening 36 is covered. The spring material 10 in the frame member 35 may not be bonded to the support layer member 31. However, in this embodiment, the position of the plurality of spring materials 10 does not change when the cushion material 30 is compressed. As described above, the end surface facing the support layer member 31 is bonded and fixed to the support layer member 31. The adjacent spring members 10 may be bonded or non-bonded, but non-bonding is preferable. If the contact surfaces of the adjacent spring members 10 are not bonded, the spring members 10 can be compressed and deformed independently of each other. The load can be absorbed effectively and the body pressure dispersibility can be improved.

  The exterior material 40 surrounds the outer surface of the cushion material 30 and is made of an appropriate material such as a cloth material or a leather material, and has a bag shape in the illustrated example.

  Note that a plurality of the cushion materials 30 may be laminated according to cushioning properties required for sofas, mattresses, etc., or may be laminated on other cushion materials made of other spring materials such as coil springs. . In that case, you may cover the whole with the said exterior | packing material 40 in the state laminated | stacked in multiple numbers or the state laminated | stacked on the other cushioning material.

In order to confirm that the spring material of the present invention has a small amount of sag, the end surface: 75 mm × 75 mm, high as a spring material made of a columnar elastic foam whose outer surface excluding both end surfaces is composed of a skin layer. Length: Polyurethane foam composed of 75 mm prisms, density 0.13 g / cm ³ (conforms to JIS-K-6400) surface hardness of skin layer outer surface is Aska F hardness 70 degrees, rebound resilience of portions excluding skin layer (JIS- K-6400-3: 2004 compliant) 25%, product name: Tormender FK, manufactured by Inoac Corporation, a spring material of an example, and a polyurethane foam having the same size and density as the example, but without a skin layer JIS-K- for each of the spring material of Comparative Example 1 and the spring material of Comparative Example 2 comprising a metal coil spring having a diameter of 75 mm and a height of 75 mm. In accordance with 6400-4: 2004, compression residual strain was repeatedly measured. As shown in FIG. 8, the measurement results show that the strain rate was 1% even when the number of repeated compressions was 320,000 in the example, whereas the strain rate was 1.8% in the comparative example 1 at 80,000 times. The strain rate is 3.3% at 10,000 times, the strain rate is 5.6% at 240,000 times, and the strain rate is 10% at 320,000 times. In Comparative Example 2, the strain rate is 1.2% and 160,000 at 80,000 times. The strain rate was 2.1%, the strain rate was 4.1% at 240,000 times, and the strain rate was 32% at 320,000 times. From this, it can be seen that the spring material of the present invention has a smaller sag than a spring material made of a metal coil spring and a spring material made of an elastic foam without a skin layer.

It is a perspective view of 1st embodiment in the spring material of this invention. It is a perspective view of 2nd embodiment in the spring material of this invention. It is a perspective view of 3rd embodiment in the spring material of this invention. It is sectional drawing of one Embodiment of the cushioning material in this invention. It is a disassembled perspective view which shows the support layer member, frame member, spring material, and elastic layer member of the cushion material. It is a perspective view which shows the state which accommodated the spring material in the frame member of the cushion material. It is a perspective view of one embodiment of a sofa using the cushion material in the present invention. It is a figure which shows the measurement result of repeated compression residual distortion.

DESCRIPTION OF SYMBOLS 10 Spring material 10A Columnar elastic foam whose outer surface excluding both end surfaces is composed of skin layers 11, 11 Both end surfaces 12 Outer surface 13 Skin layer 20 Spring material 30 Cushion material 40 Exterior material

Claims (4)

A non-breathable support layer member and a breathable elastic layer member are arranged to face each other.
Between the support layer member and the elastic layer member,
Out of the end surfaces of the columnar elastic foam when the outer surface excluding both end surfaces is made of a columnar elastic foam composed of a skin layer and is pressed along the axial direction of the columnar elastic foam A plurality of spring materials that cause air flow from at least one of them are arranged substantially parallel to each other and substantially perpendicular to the support layer member and the elastic layer member, and adjacent spring materials are in close contact with each other. Established,
Cushioning material, wherein a contact surface on which the spring member between the adjacent closely is a non-adhesive. 2. The cushion according to claim 1, wherein the plurality of spring materials are accommodated in an opening of a frame member made of an elastic body having an opening at the center and disposed between the support layer member and the elastic layer member. Wood. The cushion material according to claim 1 or 2, wherein a plurality of spring members between the support layer member and the elastic layer member are bonded to the support layer member. The spring material has a density of 0.10 to 0.16 g / cm. ³ The rebound resilience of the portion excluding the skin layer is 10 to 40%, and the outer surface hardness of the skin layer is Aska F hardness 55 to 85 degrees. Cushion material.

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