JP5030393B2 - Cushion for bed and manufacturing method thereof - Google Patents

Description

  The present invention relates to a bed cushion having a spring structure that uses a three-dimensional network structure made of synthetic resin, and a method for manufacturing the same.

  Various reclining bed cushions (also referred to as gage types) have been proposed (Patent Documents 1 to 5). Patent document 1 is completely separated and divided into a plurality of mats in order to correct the displacement spine. Patent document 2 consists of a structure which connected metal springs with a clip. Patent Document 3 is a water gaji bed in which a plurality of mats include a gel-like material layer and the mats are completely separated and divided in order to bend the upper part. Patent Document 4 is completely separated and divided into a plurality of three-dimensional network cushions in order to realize easy body cleaning and manure disposal. In Patent Document 5, when a water mattress is applied to a gagbed, the body support performance is not deteriorated by adopting a structure that minimizes the movement of water in the water bag with the back portion raised and lowered. In a normal state where the water mattress is flat, the human body is supported by a uniform pressure, and when not in use, the water mattress can be folded and stored and transported easily. A cushion body made of an elastic foam is arranged on the inner peripheral edge to form a water bag housing portion, and a plurality of water bags are arranged in a predetermined direction in the water bag housing portion. It has an elastic foam with a volume approximately the same as the internal volume of Water was encapsulated in Tabaggu, it is to completely separate and divide the plurality of cushion under the bag.

JP 47-44890 A Japanese Utility Model Publication No.59-29961 Japanese Utility Model Publication 2-74024 JP 11-318998 A JP 2003-310389 A

  Various types of general bed cushions that are not reclining bed cushions have been developed.

  However, the conventional reclining bed cushions of Patent Documents 1, 3, 4, and 5 have a problem that the cushions are separated and divided, so that a shift occurs and a step is easily formed and is difficult to use. Patent Documents 2, 3, and 5 have a problem that the weight is too heavy. Furthermore, the conventional general bed has a problem that air circulation action, strength, flexibility and the like are not sufficient.

In view of the above problems, an object is to realize a seamless structure of the bed cushion, to eliminate the displacement between the cushions and the level difference between the cushions, and to realize weight reduction.
In order to solve such a problem, the invention according to claim 1 is based on a continuous hollow filament or solid filament that uses a thermoplastic resin as a raw material or a main raw material and is entangled in a loop shape by extrusion and partially heat-bonded. A three-dimensional network structure having a spring structure, and the three-dimensional network structure has a dense surface structure in the thickness direction that is the vertical direction of the extrusion direction of the extrusion, and has a flat surface layer that is a dense portion on one side. The overall porosity is 36% to 98.4%, the outer diameter of the continuous filament is 0.3 mm to 3 mm, and penetrates in the lateral direction from the lower surface to the upper surface of the three-dimensional network structure. A plurality of continuous grooves are formed along the longitudinal direction with predetermined gaps or appropriate gaps, and a spring structure is provided that expands when the three-dimensional network structure is bent upward, sometimes, A flat surface layer, which is a dense portion, is formed on the upper and lower surfaces, and a sparse portion is formed between the two flat surface layers, and the continuous groove extends beyond the surface layer. It is a bed cushion formed up to the sparse part .

The continuous groove is preferably linear in a side view.
The continuous groove is preferably square when viewed from the side.
The continuous groove is preferably arcuate in side view.
The continuous grooves are formed at predetermined intervals or appropriate intervals along the longitudinal direction of the three-dimensional network structure, and a plurality of grooves penetrated in a short direction from the lower surface to the upper surface of the three-dimensional network structure, A three-dimensional network structure is formed at a predetermined interval or an appropriate interval along the short direction of the three-dimensional network structure, and is formed in a lattice shape including a plurality of grooves penetrating in a longitudinal direction from the lower surface to the upper surface of the three-dimensional network structure. It is preferable.
It is a three-dimensional network structure of the said continuous hollow wire, Comprising: It is preferable that the edge part of a hollow wire is welded.
In the three-dimensional network structure of the continuous hollow wire, it is preferable that an end surface facing the continuous groove is closed by heat or ultrasonic waves.
It is preferable that the continuous hollow wire has a wire diameter of 0.3 mm to 3.0 mm.
It is preferable that the continuous hollow wire has a bulk density of 0.02 to 0.9 g / cm ³ .
It is preferable that the depth of the continuous groove is 50 to 90% of the height of the three-dimensional network structure.
The width in the longitudinal direction of the continuous groove penetrating in the short direction or the width in the short direction of the continuous groove penetrating in the longitudinal direction is preferably 6 to 50% of the height of the three-dimensional network structure.
It is the said continuous hollow wire solid network structure, Comprising: It is preferable that the edge part of a continuous hollow wire is closed.

The spring structure bed cushion manufacturing method of the present invention comprises a continuous hollow filament or a solid filament which is made of thermoplastic resin as a raw material or main raw material and is entangled in a loop shape by extrusion molding and partially thermally bonded. A three-dimensional network structure having a spring structure is formed, and this three-dimensional network structure has a dense structure in the thickness direction which is the vertical direction of the extrusion direction of the extrusion, and has a flat surface layer which is a dense portion on one side. A spring structure forming step for forming a spring structure having an overall porosity of 36% to 98.4% and an outer diameter of the continuous filament of 0.3 mm to 3 mm, and a lower surface of the three-dimensional network structure A gap forming step for forming a plurality of continuous grooves penetrating in the lateral direction with a predetermined gap or an appropriate gap along the longitudinal direction by cutting while applying heat toward the upper surface. When provided with, at the time of extrusion, the flat surface layer is dense portion is formed on the upper surface and a lower surface, a three-layer structure in which sparse portions are formed between the two flat surface layers, the continuous groove exceeds the surface layer described above is formed to sparse portions and said Rukoto.
In the gap forming step, a plurality of continuous grooves penetrating in the short-side direction are cut along the longitudinal direction by a predetermined gap or an appropriate gap by cutting off the three-dimensional network structure while applying heat from the lower surface to the upper surface. And a gap forming step for forming a plurality of continuous grooves penetrating in the longitudinal direction with a predetermined gap or an appropriate gap along the short side direction.
The three-dimensional network structure may have a configuration in which the bulk density of the continuous hollow filament or the solid filament is changed between the upper part and the lower part in the thickness direction, or a structure in which the bulk density is changed on the left and right. As an example, a configuration in which the upper part is dense and the lower part is sparse can be raised.
Furthermore, a colorant, a fluorescent paint, a phosphorescent material, a negative ion generating material, activated carbon, an antibacterial agent, and the like may be mixed with the raw material resin.

  After the gap forming step, the open ends of the continuous grooves of the cut three-dimensional network structure are melted and solidified by heat or ultrasonic waves, or simultaneously with the cutting of the gap forming step, the three-dimensional network structure It is preferable to include a step of closing the open end by melting and solidifying the open end of the continuous groove by heat or ultrasonic waves.

  The present invention is a three-dimensional network structure having a spring structure composed of continuous hollow filaments or solid filaments that are thermoplastically made from a raw material or a main raw material and are randomly entangled in a loop shape by extrusion molding and partially thermally bonded. The three-dimensional network structure has a dense structure in the thickness direction, which is the vertical direction of the extrusion direction of the extrusion, has a surface layer that is a dense part on one side, and the overall porosity is 85% to 95%. Thus, the surface layer is a bed cushion having sufficient bending and increased proof strength against the number of bendings.

  It is preferable that the three-dimensional network structure having the spring structure is composed of the continuous hollow filaments, and the surface layer is composed of the continuous hollow filaments.

  The present invention is a three-dimensional network structure of a spring structure composed of continuous hollow filaments that are made of a thermoplastic resin as a raw material or a main raw material and are randomly entangled in a loop shape by extrusion and partially heat-bonded. The structure can be provided with a dense structure in the thickness direction which is the vertical direction of the extrusion direction of the extrusion, but has a dense portion on one side and a total porosity of 80% to 95%. A structure having a dense portion in a layer is used for a bed in which air vibration is generated inside and outside a continuous hollow filament having a long fiber structure on the surface layer by a sound source or a vibrating body, and the surface layer and the entire bed are amplified and vibrated. It is a cushion.

  The three-dimensional network structure of the spring structure is composed of the continuous hollow wire, and the continuous hollow wire has a surface layer, and the surface layer and the entire bed vibrate by a sound source or a vibrating body. preferable.

  The present invention is a three-dimensional network structure having a spring structure composed of continuous hollow filaments or solid filaments that are thermoplastically made from a raw material or a main raw material and are randomly entangled in a loop shape by extrusion molding and partially thermally bonded. The three-dimensional network structure has a dense structure in the thickness direction that is the vertical direction of the extrusion direction of the extrusion, a dense portion on one side, and a total porosity of 70% to 90% is sufficient. Air circulation is cool, and the inside of the structure can always be kept dry. When the overall porosity is 80% to 95%, the sleeping comfort is good and the porosity is 85% to 95%. The thing is a cushion for a bed that has sufficient air circulation action and body pressure is dispersed.

  In the present invention, the three-dimensional network structure of the spring structure has a dense structure in the width direction that is the left and right of the extrusion direction, and is composed of continuous hollow filaments. It is preferable to have a surface layer.

  The bed cushion according to claims 16 to 21, wherein the dense portion has a porosity of 50% to 80%, and the sparse portion 5c has a porosity of 80% to 95%.

  It is preferable that the outer diameter of the continuous filament is 0.5 mm to 4 mm.

According to the first to fourth aspects, it is possible to realize a seamless structure of the bed cushion, to eliminate the displacement between the cushions and the level difference between the cushions, and to realize weight reduction.

According to a third aspect of the present invention, it is preferable that a person lying on the cushion can relax by attaching a vibration device of a motor to the bed cushion so as to be able to vibrate. For the vibration, a configuration that allows various vibrations to be selected by remote control operation or the like can be considered.
In addition, it is preferable to inject air into the bed and support the body with air to disperse body pressure and prevent congestion, agitation and pressure ulcer.

According to the third aspect , the sound source or the vibrating body causes air vibrations in the surface layer of the continuous hollow wire having the long fiber structure, and the surface layer and the entire bed are amplified and vibrated.

According to claim 1 , the physical characteristics of the sparse part and the dense part are well balanced.

According to the first to fourth aspects, the sleeping comfort and the sitting comfort are good, the dispersibility of the body pressure distribution is good, the air permeability is not well steamed, and there is a sense of stability such as wrapping. Good durability, moderate repulsive force (repulsive force adjustment is easy and free), and less sag than urethane. It is clean, can be washed with water, is quick-drying, and can be disinfected (alcohol, stabilized chlorine dioxide). An antibacterial agent can be kneaded into a thermoplastic resin. Easy maintenance at home. It is useful for ecology, can be recycled, and can be incinerated as general waste. Excellent safety and secures breathing even when lying down. Weatherproof. The colorant can be easily realized by mixing with a thermoplastic resin.

  Embodiments of the present invention will be described below with reference to the drawings. The present invention is not limited to the above-described embodiment, and modifications and the like can be made without departing from the technical idea of the present invention. It will be included in the technical scope of the present invention.

  First, Embodiment 1 will be described with reference to FIG. The reclining type bed cushion 1 of Embodiment 1 has a spring structure composed of continuous hollow filaments that are made of recycled thermoplastic resin as a raw material or a main raw material and are entangled in a loop shape by extrusion and partially heat-bonded. A three-dimensional network structure 5 (see FIGS. 9 to 10 for the three-dimensional network structure 5), and a plurality of continuous grooves 1a penetrating in a short direction from the lower surface to the upper surface of the three-dimensional network structure 5 are elongated. It is formed with a predetermined gap or an appropriate gap along the direction, and the continuous groove 1a expands when the three-dimensional network structure 5 is bent upward. As shown in FIG. 1A, here, the continuous groove 1a is linear in a side view. The end of the hollow wire constituting the end surface of the continuous groove 1a is welded. The depth of the continuous groove 1a is set to 50 to 90% of the height H of the three-dimensional network structure 5. The width W in the longitudinal direction of the continuous groove 1a is set to 1 mm to 5 mm. This corresponds to 0.6 to 16.7% when the height H of the three-dimensional network structure 5 is 30 to 150 mm. FIG. 1B shows a state when the reclining bed cushion 1 made of the three-dimensional network structure 5 is bent upward, and FIG. 1C shows the reclining made of the three-dimensional network structure 5. The lower surface of the type bed cushion 1 is shown.

Here, the raw material or the main raw material which is the recycled thermoplastic resin is a PET bottle flake or chip. A PET bottle is crushed as it is and melted to form a flake. It is also suitable for the era of recycling promotion. If this is not a recycled product but a genuine product, the production cost per 1 m ² will be doubled in terms of cost, such as dry crystallization or dust removal. Can be used to reduce waste disposal costs. However, it can also be applied to thermoplastic resins other than recycled materials. For example, as thermoplastic resins, polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides such as nylon 66, polyvinyl chloride, polystyrene, copolymers and elastomers based on the above resins, and blends of the above resins Etc. A polyethylene resin mixed with vinyl acetate resin and rubber is preferable. If the raw material is thermoplastic urethane, elasticity can be maintained with low resilience.

The interior of the three-dimensional network structure 5 of Embodiment 1 is formed to have a substantially uniform density. The wire diameter of the hollow wire is 0.3 mm to 3.0 mm. The apparent density (bulk density) is preferably 0.02 to 0.9 g / cm ³ (corresponding to a porosity of 36 to 98.4%), particularly preferably 0.02 to 0.2 g / cm ³ . The three-dimensional network structure 5 is obtained by cutting an endless network structure in the length direction into an appropriate length, and is set to a size suitable for the bed of the reclining bed cushion 1.

According to the first embodiment, it is possible to realize one seamless cushion structure which is a cushion applied to a reclining bed but is not separated and divided. Thereby, it becomes the reclining-type bed cushion 1 which does not have the malfunction which a shift | offset | difference of cushions and a level | step difference arise between cushions.
Further, as shown in FIG. 1B, since the continuous groove 1a expands, the continuous groove 1a can be bent as a fulcrum. As a result, the backrest part can be raised or the leg rest part can be raised, and the cushion 1 can change the sleeping posture such as raising the upper body from the supine state or raising the leg tip. . Furthermore, since the end of the hollow wire constituting the end face of the continuous groove 1a is welded, there is an effect that water does not enter the interior by washing or the like.

  Next, Embodiment 2 will be described with reference to FIG. The reclining bed cushion 2 according to the second embodiment is substantially the same as the first embodiment except that the continuous groove 2a is triangular in a side view as shown in FIG. 2 (a). The triangular bottom surface of the continuous groove 2a is an open end. The tilt angle is preferably 10 to 20 °, but is not limited. The width W in the longitudinal direction of the continuous groove 2a is set to 10 mm to 15 mm. This corresponds to 6.6 to 50% when the height H of the three-dimensional network structure 5 is 30 to 150 mm. FIG. 2B shows a state when the reclining bed cushion 2 made of the three-dimensional network structure 5 is bent upward, and FIG. 2C shows the reclining made of the three-dimensional network structure 5. The lower surface of the type bed cushion 2 is shown.

  The second embodiment has the same effect as the first embodiment. Further, depending on the physical properties of the three-dimensional network structure 5 according to the first embodiment, bending the reclining bed cushion 2 upward may result in an distorted shape such as a compressive stress applied to the bent lower surface and wrinkles. However, this can be solved in the second embodiment.

  Next, Embodiment 3 will be described with reference to FIG. The reclining bed cushion 3 according to the third embodiment is substantially the same as the second embodiment except that the continuous groove 3a has an arc shape in a side view as shown in FIG. That is, the triangular surface of the continuous groove 2a in the second embodiment is arcuate. FIG. 3B shows a state when the reclining bed cushion 3 made of the three-dimensional network structure 5 is bent upward, and FIG. 3C shows the reclining bed made of the three-dimensional network structure 5. The lower surface of the cushion 3 for an object is shown. This embodiment has the same effect as the second embodiment.

Next, Embodiment 4 will be described with reference to FIGS. As shown in FIG. 4A, the reclining bed cushion 4 of the present embodiment has a configuration in which continuous grooves 4a are formed on all side surfaces of the four side surfaces of the reclining bed cushion 4. . That is, it is formed on the lower surface of the reclining bed cushion 4 at a predetermined interval or an appropriate interval along the longitudinal direction of the three-dimensional network structure 5, and in a short direction from the lower surface to the upper surface of the three-dimensional network structure 5. A plurality of grooves that are penetrated and a plurality of grooves that are formed at a predetermined interval or an appropriate interval along the short direction of the three-dimensional network structure 5 and are penetrated in the longitudinal direction from the lower surface to the upper surface of the three-dimensional network structure Are formed in a lattice shape (see FIG. 4C).
FIG. 4B shows a mode when one of the four side surfaces of the reclining bed cushion 4 is bent upward.

  In the fourth embodiment, in addition to the same effects as those of the first embodiment, the continuous grooves 4a are formed in a lattice shape on the lower surface of the reclining bed cushion 4, so that FIGS. As shown in (b), the reclining bed cushion 4 can be bent upward from any of the four side surfaces. Thus, for example, by placing a cushion 6 or the like on the cushion 4, it can be bent so as to be lifted from the head 7 to the back 8 of the person lying on the cushion 4 (see FIG. 5 (a)). ), And can be bent so that the side of the person lying down is lifted (see FIG. 5B). By applying the cushion 4 to the conventional fixed bed, not only can the same effect as the reclining bed, that is, raising the leg rest or raising the backrest, etc. It is also possible to raise the right or left half of the body from the supine state.

  Furthermore, in this embodiment, the lower surface of the cushion 4 is divided into a plurality of regions by forming the continuous grooves 4a in a lattice shape on the lower surface of the reclining bed cushion 4. In the present embodiment, as shown in FIG. 4C, 16 blocks 4c are formed by dividing into 16 blocks. Then, by placing a cushion 6 or the like on the block 4c, only a part of the entire cushion can be raised as shown in FIG. 6 (a). Further, as shown in FIGS. 6B and 6C, a plurality of portions can be raised in the entire cushion. As a result, it is possible to provide a cushion that can be laid down in an easy posture not only by healthy persons but also by elderly people, physically handicapped persons, persons who are injured or undergoing medical treatment. It also helps to prevent congestion, discomfort and pressure ulcers.

Note that when the three-dimensional network structure 5 of Embodiments 1 to 4 is cut with a cutter, a circular saw, or the like, the ends of the continuous hollow filaments on the cut surfaces (here, the continuous grooves 1a to 4a and the four side surfaces) are opened. However, the continuous hollow wire may be cut by contact with a melting means such as a heater or hot water to melt and solidify the cut surface, and the end of the continuous hollow wire may be closed. . The temperature range of the treatment is preferably 60 ° C to 300 ° C. In addition, the pressure range of the treatment is preferably 0.01 to 10 MPa.
Specifically, it is possible to use a hot plate, a hot wire, an ultrasonic knife, an ultrasonic cutter, or the like. For example, as shown in FIG. 7 (a), by forming the continuous groove 1a with heat or ultrasonic waves, the cut surface is fused, the strength is increased, and the gaps at the ends are further closed. This is preferable because water and bacteria can be prevented from entering the strip.
When the continuous groove 1a is processed and formed with a knife or a circular saw, as shown in FIG. 7 (b), a gap is generated in the cut surface, thereby causing a problem in strength, and bacteria and There is a risk of water intrusion.

  The bed cushion 5 shown in FIG. 8A is an example in which continuous grooves 1a, 2a, 3a or 4a are formed up to the surface layer 5a.

  As shown in FIG. 8B, the continuous groove 9a may be formed with a narrow interval (10 mm to 60 mm, preferably 20 to 30 mm). In this case, the continuous groove 9a is formed not by V-cutting but by using a hot plate 9d configured by connecting the thin plate 9c to the iron plate 9b at right angles, and the thin plate 9c is perpendicular to the surface layer 5b. After pressing and forcing or natural cooling, the hot plate 9d is pulled out.

  The three-dimensional network 5 shown in FIGS. 9 and 10 is the material of Embodiments 1 to 4, and as shown in FIGS. 9 and 10, both side regions 5a and 5b in the extrusion direction are dense, and the inner region 5c is sparse. It has become. As shown in FIG. 10A, the continuous filament is a hollow structure (tube). Of the two side regions 5a and 5b, 5a is a side on which a human body rides when cushioned, and 5b is a side on which a bed is placed. In the present embodiment, the both side regions 5a have a higher density than the both side regions 5b. The density of the two side areas 5a and 5b can be changed as appropriate.

  Further, the three-dimensional network structure 5 has a structure as shown in FIG. 9A, but can be used as a reclining bed material, but can also be implemented for a general bed other than the reclining bed. Specifically, the bed cushion 5 is a continuous hollow filament (see FIG. 10) or a solid filament that is made of thermoplastic resin as a raw material or main raw material and is entangled in a loop shape by extrusion and partially thermally bonded. A three-dimensional network structure 5 having a spring structure composed of the following: a three-dimensional network structure 5 is provided with a dense structure in the thickness direction which is the vertical direction of the extrusion direction of extrusion molding, and a surface which is a dense portion 5a, 5b on one side It has layers 5a and 5b, and the total porosity is 85% to 95%. The three-dimensional network structure 5 having a spring structure is composed of continuous hollow filaments, and the surface layers 5a and 5b are composed of continuous hollow filaments.

  As shown in FIG. 9 (a), the three-dimensional network structure 5 is a continuous hollow filament that uses a thermoplastic resin as a raw material or a main raw material, is entangled in a loop shape by extrusion and is partially thermally bonded (see FIG. 10). The three-dimensional network structure 5 having a spring structure, which is formed of a dense structure 5a on one side, can be provided with a dense structure in the thickness direction which is the vertical direction of the extrusion direction of extrusion molding. , 5b, and the overall porosity is 80% to 95%, and the structure having the dense portions 5a, 5b in the surface layers 5a, 5b is formed on the surface layers 5a, 5b by a sound source or a vibrating body. Air vibration is generated inside and outside the continuous hollow wire having a long fiber structure, and the surface layers 5a and 5b and the entire bed are amplified and vibrated.

  As shown in FIG. 9 (a), the three-dimensional network structure 5 is a continuous hollow filament that uses a thermoplastic resin as a raw material or a main raw material, is entangled in a loop shape by extrusion and is partially thermally bonded (see FIG. 10). ) Or a three-dimensional network structure 5 having a spring structure composed of solid filaments, and the three-dimensional network structure 5 has a dense structure in the thickness direction which is the vertical direction of the extrusion direction of the extrusion, and has a dense portion on one side. 5a and 5b, the overall porosity is 70% to 95%, there is sufficient air circulation, it is cool and the inside of the structure can always be kept dry, and the overall porosity is 80% to Those with 95% have good sleeping comfort, and those with a void ratio of 85% to 95% are bed cushions that have sufficient air circulation and disperse body pressure.

  As shown in FIG. 9B, the three-dimensional network structure 5 has a dense structure in the width direction that is the left and right of the extrusion direction, and the continuous three-dimensional network structure (see FIG. 10). ), And has a surface layer 5e and an inner layer 5f in a four-sided continuous hollow filament. The surface layer 5e surrounds the inner layer 5f along the extrusion direction.

  The porosity of the dense portions 5a and 5b is 50% to 80%, and the porosity of the sparse portion 5c is 80% to 95%. The continuous filament has an outer diameter of 0.5 mm to 4 mm.

(3D network structure manufacturing equipment)
Next, the three-dimensional network-structure manufacturing apparatus 10 will be described.
As shown in FIG. 12, the three-dimensional network structure manufacturing apparatus 10 is configured to drive an extruder 11, a pair of endless conveyors 14 and 15 (see FIG. 14) having endless belts 12 and 13, and a drive for driving the endless belts 12 and 13. It consists of a motor 16, a chain 17 and a gear 17 that changes the moving speed of the endless belts 12, 13, a water tank 18 that partially submerses the pair of endless conveyors 14, 15, a control device 19, and other instruments. ing.

  As shown in FIG. 14, the endless conveyor 14 includes a drive shaft 14b having a sprocket 14a around which an endless chain 12a is wound, and a driven shaft 14d having a sprocket 14c. The endless conveyor 15 is driven in synchronism with the endless conveyor 14, and includes a driven shaft 15b having a sprocket 15a around which an endless chain 13a is wound, and a driven shaft 15d having a sprocket 15c. I have.

  As shown in FIG. 12, the extrusion molding machine 11 includes a container 31, a raw material supply port 32 provided at the top of the container 31, a die 33, a base 34 that can be detachably fixed to a lower end portion of the die 33, and the like. The temperature range inside the die of the extruder 11 can be set to 100 to 400 ° C., the extrusion amount can be set to 20 to 200 kg / hour, and the like. The pressure range of the die 33 is 0.2 to 25 MPa, for example, a discharge pressure of a 75 mm screw. If the thickness of the three-dimensional network structure 5 exceeds 100 mm, it may be necessary to make the die pressure uniform by a gear pump or the like. Therefore, it is necessary to increase the pressure in the die by a gear pump or the like in order to discharge the hollow wire evenly from the entire area inside the die 33. At this time, in order to form the shape of the three-dimensional network structure, each surface of the endless conveyors 14 and 15 is configured to be freely movable. The shape (hole density or diameter) of the die 34 of the die 33 and the endless conveyors 14 and 15 A product having a desired density and strength can be manufactured according to the conveyance speed, and various requirements of the product can be satisfied.

  The three-dimensional network-structure manufacturing apparatus 10 of the present embodiment is a four-sided molding machine provided with a pair of rolls 56 and 57 shown in FIG. 15 in addition to the endless conveyors 14 and 15 for drawing a plurality of filaments. That is, the endless conveyor 14 having the drive shaft 14b and the driven shaft 14d, the endless conveyor 15 having the driven shafts 15b and 15d, and the rotation axis of the endless conveyors 14 and 15 are orthogonal to the longitudinal ends thereof. A pair of rolls 56 and 57 provided with rotatable rotating shafts 56a and 57a are arranged. The drive shaft 14b is provided with bevel gears 54b and 54c, respectively, and the rotary shafts 56a and 57a are also provided with bevel gears 56b and 57b, respectively, and the bevel gears 54b and 54c and the bevel gears 56b and 57b are engaged with each other. 14b and 15b are synchronously driven by the motor M via the chain C. Therefore, the rotary shafts 56a and 57a are also synchronously driven. The other ends of the rotating shafts 56a and 57a are supported by bearings 58a and 58b.

  As shown in FIG. 15 (c), a pair of short endless conveyors 59a and 59b having the same structure as the endless conveyors 14 and 15 may be arranged orthogonally. In this case, the molding can be performed more precisely and the dimensional accuracy is improved.

  As shown in FIG. 15D, it can be manufactured using four-sided molding. Further, as shown in FIG. 15E, three-side molding can be performed using this. That is, depending on the type of the three-dimensional network structure 5, if two series of dies 33 are provided in parallel to extrude two hollow wire assemblies, the production efficiency is doubled.

  As shown in FIG. 16A, as a modified form, instead of the above-described synchronous drive, a drive source (motor or the like) is provided, respectively, and endless conveyors 64 and 65 and rolls 66 and 67 (may be used as an endless conveyor) It is also possible to adopt a configuration in which these are driven independently. That is, in the case of three-sided or four-sided molding, the endless conveyors 64 and 65 having the rotation shafts 64a and 65a, and the endless conveyors 64 and 65 can be rotated with their rotation axes orthogonally arranged at the longitudinal ends. A pair of rolls 66 and 67 having rotating shafts 66a and 67a are arranged. The rotating shafts 66a and 67a are each provided with a motor M and are driven independently. The other ends of the rotary shafts 66a and 67a are supported by bearings 68a and 68b.

  As another modification, as shown in FIG. 16B, the pair of rolls 66 and 67, the rotating shafts 66a and 67a, the bearings 68a and 68b, and the motor M are deleted in the above-described example, and polytetrafluoroethylene is processed on the surface. By providing the slidable curved plates 69a and 69b where the rolls 66 and 67 are located, the drive mechanism can be simplified. The curved plates 69a and 69b are formed in an arc shape in a side view and in a rectangular shape in a plan view.

  The hole of the cap 34 has a shape in which the filaments descend in series, and there is a hole from which the hollow fiber descends downward. The hole is formed in an annular shape. The holes may be provided at regular intervals or non-equal intervals. The holes can have various arrangements such as a staggered shape or an orthogonal shape. When it is desired to change the arrangement density, a method of actively increasing the density only in the end region may be used. Various modifications of the shape of the base 34 can satisfy various requirements of the product.

(Manufacturing method of reclining bed cushion)
The manufacturing method of the reclining bed cushion of the present invention is a spring structure composed of continuous hollow filaments that are made of thermoplastic resin as a raw material or a main raw material and are entangled in a loop shape by extrusion and partially heat-bonded. A step of forming the three-dimensional network structure 5 and a cutting operation while applying heat from the lower surface to the upper surface of the three-dimensional network structure 5, thereby forming a plurality of continuous grooves 1 a to 4 a in the short direction along the longitudinal direction. And forming with a predetermined gap or an appropriate gap. A plurality of continuous grooves 4a in the longitudinal direction may be formed at predetermined intervals or at appropriate intervals along the short direction by cutting while applying heat from the lower surface to the upper surface of the three-dimensional network structure 5. Details will be described below.

The three-dimensional network structure 5 having a spring structure is formed as follows.
As shown in FIG. 13, the molten thermoplastic resin is extruded downward from a plurality of dies 33, and is transported downward in water by a pair of endless conveyors 14 and 15. The die 34 of the die 33 has a plurality of holes, and the extruded wire becomes a hollow wire. The hollow filaments made of the molten thermoplastic resin descend naturally from the base 34 and are drawn between the endless conveyors 14 and 15 partially submerged through the shooters 20 and 21. Since the interval between the endless conveyor 14 and the endless conveyor 15 is set narrower than the width of the extruded filament aggregate, both sides or one side of the aggregate of the thermoplastic resin lowered by the shooters 20 and 21 After the surface portion falls on the upper ends of the endless conveyors 14 and 15, it moves to the inside of the molten thermoplastic resin aggregate and is wound in a dense state (see FIG. 13). At this time, the speed at which the filaments that have fallen on the endless conveyors 14 and 15 are drawn is slower than the speed at which the endless conveyors 14 and 15 are naturally lowered and pulled as they are. Therefore, both surfaces (or one surface) of the aggregate of filaments have a lower porosity than the central portion that has been dropped into water. Since the surface portion where the porosity is low has more intersections than the central portion where the porosity is high, it becomes a dense portion of the hollow wire and the strength is increased. Moreover, the central part which fell in water as it is becomes a sparse part of a hollow filament. By this method, the surface which contacts the endless conveyors 14 and 15 among the aggregates of the filaments is arranged, and two surfaces of the aggregates of the filaments, that is, the upper and lower surfaces of the bed cushions 1 to 4 are formed. . Further, both side surfaces of the three-dimensional network structure 5 are also formed by the rolls 56 and 57 or the endless conveyors 59a and 59b shown in FIG.

  As a raw material of the three-dimensional network structure 5, a resin obtained by heating and drying a vinyl acetate resin to prevent hydrolysis and adding an agent for improving the finish appropriately, an antibacterial agent, or the like may be used.

  The pair of shooters 20 and 21 has water flowing from the upper side to the lower side on the surface, and is covered with a water permeable sheet, for example, a cloth. It can be formed. The shooters 20 and 21 have left and right symmetric inclined surfaces, and the width gradually decreases as they go downward.

  In order to function as the three-dimensional network 5, the overall porosity depends on the use conditions of the reclining bed cushion, but the test results indicate that the range of the porosity of 50% to 98% is good. Obtained. That is, it becomes hard when the density is high, and soft when the density is low. In order to exhibit a sufficient function as the bed cushions 1 to 4, it was found that the porosity should be at least 70% or more. That is, if the porosity is smaller than 70%, the cushioning properties of the reclining bed cushions 1 to 4 may not be improved as expected. About this porosity, it is good to design suitably in the range of 70%-98% according to the use of the three-dimensional network-structure 5.

  Porosity = 100 − {(B ÷ A) × 100}. A is the resin specific gravity multiplied by the volume of the three-dimensional network structure 5, and B is the weight of the three-dimensional network structure 5.

As the thermoplastic resin used here, a vinyl acetate resin or a polyethylene resin mixed with rubber is used as a raw material or a main raw material. However, as a main raw material, it can be processed with a normal extruder such as a polymer such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), or a blend of a plurality of polymers. If it is resin, there is no problem.
The hardness of the three-dimensional network structure 5 can be changed by changing the bulk density, the material of the synthetic resin, and the like. The control of the bulk density can be realized by the control of the resin yarn extrusion speed control of the extrusion molding machine 11, the rotation speed control of the take-up machine, and the like.

When the width of the sheet was 1.0 m and the thickness was 100 mm, it was confirmed that the density changed by changing the speed of the endless conveyor in order to confirm that the density changed.
Further, it was confirmed that the density changed due to the change in the discharge amount of the extruder 11.

  In the present embodiment, a single screw extruder having a screw diameter of 75 mm, a die 33 having an area of 1.5 m × 150 mm, and a die having a diameter of 0.5 mm and having approximately 3500 holes H at almost equal intervals. 34 was attached. A water tank 18 having a water level is installed at a position of about 120 mm below the die 33, and a pair of endless conveyors 14 and 15 having a width of 1.2 m are spaced apart by 50 mm, and the upper parts of the endless conveyors 14 and 15 are about 40 mm from the water surface. It was installed almost vertically so that it could come out. The shooters 20 and 21 are installed above the endless conveyors 14 and 15.

  With this apparatus, the temperature of the die 33 is controlled so that the resin temperature becomes 240 ° C. while plasticizing the vinyl acetate resin by applying heat, and the molten resin discharged from the die 34 at an extrusion amount of 120 kg per hour is controlled. The assembly was extruded between them so that both sides of the assembly fell on the endless conveyors 14 and 15. The take-up speed of the endless conveyors 14 and 15 at this time was 0.7 m / min. The molded product that has been sandwiched between the endless conveyors 14 and 15 and moved downward changes its direction at the lower part of the water tank 18, moves from the side opposite to the extruder to the water surface, and when it exits the water tank 18, either compressed air or Water was blown away with a vacuum pump.

The three-dimensional network structure 5 thus obtained has a width of 1500 mm to 2000 mm, a thickness of 30 to 150 mm (preferably 60 to 120 mm), and a density of 0.02 g / cm ^{3 to} 0.2 g / cm. ³ was obtained. If appropriate, cut to a size for a reclining bed cushion. The cutting is preferably in the direction perpendicular to the extrusion direction. That is, it is preferable that the cut surface of the three-dimensional network structure 5 is cut so as to be both ends in the longitudinal direction of the reclining bed cushions 1 to 4.

  Next, a cut surface is formed by making a cut from the lower surface to the upper surface with a heated cutter in the three-dimensional network structure 5. A plurality of continuous grooves 1a to 4a penetrating in the lateral direction from the lower surface to the upper surface of the three-dimensional network structure 5 are formed along the longitudinal direction at predetermined intervals or at appropriate intervals. The cut surface to be formed is a line, a square, an arc or the like in a side view. In the case of the lattice-like continuous grooves 4a, in addition to the formation of the continuous grooves, a plurality of continuous grooves 4a penetrating in the longitudinal direction are formed at predetermined intervals or appropriate intervals along the short direction.

  After the formation of the cut surface or simultaneously with the formation of the cut surface, the open ends of the continuous filaments (here, the continuous grooves 1a to 4a and the front and rear side portions) are welded by heat, solidified and closed. That is, the continuous hollow wire has an open end (see A in FIG. 10) on the cut surface of the three-dimensional network structure 5, but the open end of the continuous hollow wire is in contact with a melting means such as a heater, hot water, and ultrasonic waves. Thus, the reclining bed cushion 1 or 4 shown in FIG. In FIG. 11, the continuous groove 1a or 4a of the filament is formed, but the reclining bed cushion 2 or 3 may be formed by forming the rectangular continuous groove 2a and the arc-shaped continuous groove 3a, respectively. . The temperature range of the treatment is preferably 60 ° C to 300 ° C. In addition, the pressure range of the treatment is preferably 0.01 to 10 MPa. When cutting and melting and solidifying are performed simultaneously, the continuous filament is cut by the heater plate. In this case, there is an effect of preventing the invasion of liquid (such as water) and solid (such as dust) into the continuous hollow wire, and suppressing the propagation of germs and the like.

  The size of the bed of the three-dimensional network structure is 1910 mm long, 840 mm wide, and 75 mm thick. The soft spring type shown in FIG. 17 has a weight of 10.5 kg, a porosity of 91%, and an outer diameter of the wire 2 to 2 mm. The type having a hard spring stiffness of 3 mm and FIG. 18 has a weight of 14.5 kg, a porosity of 88%, and an outer diameter of the filament of 2 to 3 mm. A reclining groove is not formed in a general bed structure. The body pressure dispersion in a state where a subject weighing 60 kg lies on the bed cushion was measured for each position of the bed. Body pressure was divided into 18 classes by color (right graph), and a color distribution diagram (left graph) for each measurement position was created. The shades shown in the divided upper, middle, and lower sections respectively indicate the scapula, the buttocks, and the buttocks. As a result, as shown in FIGS. 17 and 18, it is recognized that the body pressure is dispersed below 32 mmHg (4266 Pa), which is the limit at which pressure Ulcer is generated.

  According to the bed cushions 1 to 4 of the present invention, it is possible to provide a bed cushion that is clean and easy to use because it can be washed and dried quickly. In addition to the fact that each of the hollow filaments itself functions as an air cushion, it can be bent at an appropriate location, so that a comfortable bed cushion can be provided. Suitable for hospitals, general households, especially those who need care.

(A) is a perspective view of the reclining type bed cushion 1 of Embodiment 1, (b) is a perspective view when the cushion 1 is bent, and (c) is a bottom view of the cushion 1. (A) is a perspective view of the reclining type bed cushion 2 in Embodiment 2, (b) is a perspective view of the cushion 2 when bent, and (c) is a bottom view of the cushion 2. FIG. (A) is a perspective view of the reclining type bed cushion 3 in Embodiment 3, (b) is a perspective view when the cushion 3 is bent, and (c) is a bottom view of the cushion 3. FIG. (A) is a perspective view of the reclining type bed cushion 4 in Embodiment 4, (b) is a perspective view when the cushion 4 is bent, and (c) is a bottom view of the cushion 4. (A) is explanatory drawing which bent the reclining type bed cushion 4 in Embodiment 4 upward, (b) is explanatory drawing which bent the lateral direction of this cushion 4 upward. (a) is the perspective view which raised one part of the cushion 4 for reclining type beds in Embodiment 4, (b) is the perspective view at the time of raising several places among this cushion 4, (c) is this cushion It is explanatory drawing at the time of raising several places among 4. FIG. (A) is the figure which processed the continuous groove | channel 1a of Embodiment 1 using a hot plate, a hot wire, an ultrasonic knife, an ultrasonic cutter, etc., (b) is implemented using a knife and a circular saw. It is the figure which processed the continuous groove | channel 1a of the form 1. FIG. (A) is a perspective view of the two-surface molded three-dimensional network structure 5 that is a material of Embodiments 1 to 4, and (b) is a perspective view of the four-surface molded three-dimensional network structure 5, and a general bed Applicable to cushions. (A) is sectional drawing of the cushion 4 of this Embodiment 1-4, (b) is sectional drawing of the cushion 4 of Embodiment 5. FIG. It is a perspective view of the three-dimensional network structure 5 used as the raw material of this embodiment. It is a front view of reclining type bed cushions 1 and 4 of the spring structure of Embodiments 1 and 4. It is a perspective view of the three-dimensional network-structure manufacturing apparatus 10 of this embodiment. It is explanatory drawing which shows the operation | movement condition of the three-dimensional network-structure manufacturing apparatus 10 of this embodiment. (A), (b) is the side view and front view of the endless conveyors 14 and 15 of the three-dimensional network-structure manufacturing apparatus 10. (A) is a top view of the endless conveyors 14 and 15 of the three-dimensional network-structure manufacturing apparatus 10 of this embodiment, (b) is a side view of the three-dimensional network-structure manufacturing apparatus 10, (c) is other 4D is a side view of the four-sided three-dimensional network structure manufacturing apparatus 10, FIG. 3D is a plan view showing the four-surface molding by the three-dimensional network structure manufacturing apparatus 10, and FIG. 3 is a plan view showing a state of three-surface molding by the apparatus 10. (A) is a plan view of the endless conveyors 14 and 15 of the three-dimensional network structure manufacturing apparatus 10 having an independent drive structure in the case of four-side molding, and (b) is the endless conveyors 14 and 15 provided with curved plates 69a and 69b on the end surfaces. FIG. It is explanatory drawing which shows distribution of the body pressure dispersion | distribution of the type with a soft spring rigidity of an Example. It is explanatory drawing which shows distribution of the body pressure dispersion | distribution of the type whose spring rigidity of an Example is hard.

Explanation of symbols

1, 2, 3, 4 ... Reclining bed cushions 1a, 2a, 3a, 4a ... Continuous groove
5 ... Three-dimensional network structure (bed cushion) 10 ... Three-dimensional network structure manufacturing apparatus
11 ... Extruder 12,13 ... Endless belt
14, 15, 59a, 59b, 64, 65 ... endless conveyor 33 ... die 34 ... base

Claims (4)

It is a three-dimensional network structure of a spring structure composed of continuous hollow filaments or solid filaments that are entangled randomly in a loop shape by extrusion molding and partially heat-bonded using thermoplastic resin as a raw material or main raw material,
The three-dimensional network structure has a dense structure in the thickness direction, which is the vertical direction of the extrusion direction of the extrusion, has a flat surface layer that is a dense part on one side, and the overall porosity is 36% to 98.4%. With
The outer diameter of the continuous filament is 0.3 mm to 3 mm,
Forming a plurality of continuous grooves penetrating in the lateral direction from the lower surface to the upper surface of the three-dimensional network structure with a predetermined gap or an appropriate gap along the longitudinal direction;
The groove expands when the three-dimensional network structure is bent upward;
With spring structure ,
A flat surface layer that is the dense portion is formed on the upper surface and the lower surface at the time of extrusion molding, and a three-layer structure in which a sparse portion is formed between the two flat surface layers. Bed cushion that is formed from the surface layer to the sparse part . Using a thermoplastic resin as a raw material or main raw material, a three-dimensional network structure with a spring structure composed of continuous hollow filaments or solid filaments that are randomly entangled in a loop shape and partially thermally bonded by extrusion molding, The three-dimensional network structure has a dense structure in the thickness direction, which is the vertical direction of the extrusion direction of the extrusion, has a flat surface layer that is a dense part on one side, and the overall porosity is 36% to 98.4%. A spring structure forming step for forming a spring structure in which the outer diameter of the continuous filament is 0.3 mm to 3 mm;
A gap forming step of forming a plurality of continuous grooves penetrating in the short-side direction with a predetermined gap or an appropriate gap along the longitudinal direction by cutting while applying heat from the lower surface to the upper surface of the three-dimensional network structure;
Equipped with a,
A flat surface layer that is the dense portion is formed on the upper surface and the lower surface at the time of extrusion molding, and a three-layer structure in which a sparse portion is formed between the two flat surface layers. Bed cushion manufacturing method beyond the surface layer formed up sparse portions and said Rukoto. A structure having a dense portion in the surface layer generates air vibrations on the inside and outside of the continuous hollow wire having a long fiber structure on the surface layer by a sound source or a vibrating body, and the surface layer and the entire bed are amplified and vibrated. , three-dimensional network structure of said spring structure, said consisted of a continuous hollow filament, said there is a continuous hollow filament to the surface layer, by its entire surface layer and the bed is a sound source or a vibration body, that vibrate bed cushion of 請 Motomeko 1.   The three-dimensional network structure of the spring structure has a dense structure also in the width direction that is the left and right of the extrusion direction, and is composed of continuous hollow filaments, and has a surface layer on the four-sided continuous hollow filaments The cushion for beds in any one of Claims 1-3.

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