JP5333967B2 - Cushion material - Google Patents
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- JP5333967B2 JP5333967B2 JP2008332981A JP2008332981A JP5333967B2 JP 5333967 B2 JP5333967 B2 JP 5333967B2 JP 2008332981 A JP2008332981 A JP 2008332981A JP 2008332981 A JP2008332981 A JP 2008332981A JP 5333967 B2 JP5333967 B2 JP 5333967B2
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Description
本発明はプロファイル加工により表面に凸部と凹部とを交互に配してなるウレタンフォームよりなるクッション材に関する。 The present invention relates to a cushion material made of urethane foam in which convex portions and concave portions are alternately arranged on the surface by profile processing.
従来、天然繊維としての木綿，絹，羊毛等の他、合成繊維のわたが寝具の詰物として使用されているが、その他にクッション材として単独に或いは前記繊維と混用してウレタンフォーム等よりなる弾性体がクッション材として使用されている。 Conventionally, cotton, silk, wool, etc. as natural fibers, and synthetic cotton wadding have been used as fillings for bedding. In addition, elasticity made of urethane foam, etc., alone or mixed with the above fibers as a cushioning material. The body is used as a cushioning material.
即ち、スポンジ本体の一面に凸部と凹部を交互に縦横に配したものが知られている。このスポンジ本体は、就寝時スポンジ本体の凹凸を人体と接する面に使用し、使用中に身体が動くことで凸部と接する身体に対し凸部がマッサージ効果を生ぜしめると共に、凹凸の間隙により通気性を良好に保てるという作用を生じ褥瘡を防止する効果を発揮する。然し、このスポンジ本体は、単一のスポンジ体をプロファイル加工しているために、体重を支え或は身体に刺激を与えるために身体に接した際に凸部全体が座屈し荷重を支えされないような事態が生するようなことも考えられる（特許文献１）。 That is, a sponge body is known in which convex portions and concave portions are alternately arranged vertically and horizontally on one surface. This sponge body uses the unevenness of the sponge body at the time of sleeping on the surface that contacts the human body, and when the body moves during use, the convex part creates a massage effect on the body that touches the convex part, and also the ventilation between the uneven parts It has the effect of maintaining good sex and exerts the effect of preventing pressure ulcers. However, since this sponge body is profiled with a single sponge body, the entire convex part buckles when it comes in contact with the body in order to support the body weight or to stimulate the body so that the load is not supported. It is also conceivable that a serious situation will occur (Patent Document 1).
また、硬度の異なるウレタンフォームを積層後にプロファイル加工を施したクッション材も知られている。このクッション材は、高密度ウレタンフォームの表裏面に高通気性のウレタンフォームを積層した三層構造体とし、この三層構造体を、凹凸セグメントを有する一対のロールで挟んで圧縮し厚味中央部を切断刃で切断して切断面凹凸の連続としたクッション体としている。 A cushioning material is also known in which urethane foams having different hardnesses are profiled after being laminated. This cushion material is a three-layer structure in which high-breathability urethane foam is laminated on the front and back surfaces of a high-density urethane foam, and this three-layer structure is compressed by sandwiching it between a pair of rolls having uneven segments. It is set as the cushion body which cut | disconnected the part with the cutting blade and made the cut surface unevenness | corrugation continuous.
然し、この態様である通気性は良好に維持出来るが、凸部の保形性を保つ手段は講じられていない。
よって、低反発ウレタン層を挟んだ三層構造としたクッション材もあるが、凸部の中間層にあって低反発ウレタン層のための凸部に座屈が生ずる恐れがあり、凸部が本来有している就寝者への刺激、体重の支え等が充分に行えないような事態の発生も考えなければならない（特許文献２，３）。
即ち、これらのクッション材等については、使用時に凸部が就寝者の体重を受け或いは就寝者の動きによって倒屈する事態が生ずるのを防ぐ手段について配慮されていない。
Therefore, some cushioning materials have a three-layer structure with a low-resilience urethane layer in between, but there is a risk of buckling in the convex part for the low-resilience urethane layer in the intermediate layer of the convex part. It is also necessary to consider the occurrence of a situation where it is not possible to sufficiently support the sleepers who have them, support the weight, etc. (Patent Documents 2 and 3).
That is, with respect to these cushioning materials and the like, no consideration is given to means for preventing the convex portion from receiving the weight of the sleeping person or being bent by the movement of the sleeping person during use.
上記の点に鑑みて、本発明は、プロファイルカットされてなる凸部をその中間高さ位置で硬くすることにより凸部の倒屈を防ぎ、指圧効果を高め、かつ、体圧分散性が良好であり、残量ひずみの少ないクッション材を提供するものである。 In view of the above points, the present invention prevents the convex portion from being bent by hardening the convex portion that has been profile-cut at the intermediate height position, improves the acupressure effect, and has good body pressure dispersibility. Therefore, the present invention provides a cushioning material with less residual strain.
本クッション材は、上記の課題を達成するために発明されたもので、請求項１記載の発明にあっては、高硬度ウレタンフォーム層の両面に、低硬度ウレタンフォーム層を積層接着し、接着剤により一体化してなる三層シートを、前記両面の低硬度ウレタンフォーム層に達するプロファイル加工を施して、凸部の高さ方向中間部位に接着層で挟まれた高硬度ウレタンフォーム層を位置せしめ、かつ、前記接着層は、高硬度ウレタンフォーム層より高い硬度の接着剤を含む薄い接着層としてなるものとした。 The present cushioning material was invented to achieve the above-mentioned problems. In the invention according to claim 1, the low-hardness urethane foam layer is laminated and bonded to both surfaces of the high-hardness urethane foam layer. The three-layer sheet integrated with the agent is subjected to profile processing that reaches the low-hardness urethane foam layer on both sides, and the high-hardness urethane foam layer sandwiched by the adhesive layer is positioned at the intermediate part in the height direction of the convex part And the said adhesive layer shall become a thin adhesive layer containing the adhesive agent whose hardness is higher than a high-hardness urethane foam layer.
請求項１記載のクッション材は、高硬度ウレタンフォーム層の両面に、低硬度ウレタンフォーム層を積層接着し、接着剤により一体化してなる三層シートを、前記両面の低硬度ウレタンフォーム層に達するプロファイル加工を施して、凸部の高さ方向中間部位に接着層で挟まれた高硬度ウレタンフォーム層を位置せしめたことを特徴とする凸部と、凹部とを交互に配してなるものであるため、クッション材は形成された凸部の高さ方向の中央部分が、高硬度のウレタンフォーム層となり、就寝者がクッション材上に横たわるような場合、凸部が前記体重を受けても凸部が座屈し倒伏するようなことがなく就寝者を突き上げるような状態となり良好にマッサージ効果を与えることが可能となり、かつ、体圧分散性が良好であり、残量ひずみの少ないクッション材を得ることが出来る。
また、高硬度ウレタンフォーム層の両面に積層された低硬度ウレタンフォーム層は、それら各層の接着面に塗布された接着剤により接着され、両層の接着部位には高硬度ウレタンフォーム層より高い硬度の、接着剤を含む薄い接着層が、接着面に形成されているために、前記薄い接着剤層が、凸部を形成する高硬度ウレタンフォーム層の上下面において、凸部の妄動を阻止するように固定状態を保持することになり、凸部を強化することとなる。
The cushion material according to claim 1, wherein a low-hardness urethane foam layer is laminated and bonded to both surfaces of a high-hardness urethane foam layer, and a three-layer sheet formed by integrating with an adhesive reaches the low-hardness urethane foam layers on both sides. Protruding parts and concave parts are arranged alternately by applying profile processing and positioning a high-hardness urethane foam layer sandwiched between adhesive layers at the intermediate part in the height direction of the convex parts. Therefore, when the cushion material is formed with a high-hardness urethane foam layer at the center in the height direction of the convex portion formed, and the sleeping person lies on the cushion material, the convex portion is convex even when receiving the weight. The body does not buckle and lie down and push up the sleeper, giving a good massage effect, good body pressure dispersibility, and low residual strain. It is possible to obtain gastric cushion material.
The low-hardness urethane foam layer laminated on both sides of the high-hardness urethane foam layer is bonded by the adhesive applied to the adhesive surface of each layer, and the adhesive part of both layers has a higher hardness than the high-hardness urethane foam layer. Since the thin adhesive layer containing the adhesive is formed on the adhesive surface, the thin adhesive layer prevents the turbulence of the convex portions on the upper and lower surfaces of the high-hardness urethane foam layer forming the convex portions. Thus, the fixed state is maintained, and the convex portion is strengthened .
本発明のクッション材を図面と共に次に説明する。
図１は本発明クッション材の縦断正面図、図２は平面斜視図、図３はプロファイル加工を行なう装置の概略図である。
本発明クッション材１は、高硬度ウレタンフォーム層２の両面に、低硬度ウレタンフォーム層３，３を重ねて積層し、高硬度ウレタンフォーム層２の両面に塗布した接着剤４によって一体化した三層シート５よりなる。そして、三層シート５をプロファイル加工して低硬度ウレタンフォーム層３の一面に複数の凸部６と凹部７とが縦横等間隔に並列したクッション材１とする。
Next, the cushioning material of the present invention will be described with reference to the drawings.
1 is a longitudinal front view of the cushion material of the present invention, FIG. 2 is a plan perspective view, and FIG. 3 is a schematic view of an apparatus for performing profile processing.
The cushion material 1 of the present invention is formed by laminating low hardness urethane foam layers 3 and 3 on both sides of a high hardness urethane foam layer 2 and integrating them with an adhesive 4 applied to both sides of the high hardness urethane foam layer 2. It consists of a layer sheet 5. Then, the three-layer sheet 5 is profile processed to form a cushion material 1 in which a plurality of convex portions 6 and concave portions 7 are arranged in parallel at equal intervals in the vertical direction on one surface of the low-hardness urethane foam layer 3.
上記三層シートは高硬度ウレタンフォーム層２の両面に接着剤を塗布し、その面に低硬度ウレタンシート層３を接着するが、塗布された接着剤は各シートの表面のウレタンフォームに浸透し接着剤の固化と共に接着剤が塗布された部分の硬度は更に高くなっている。この三層シート５をプロファイル加工装置８に導入してプロファイル加工を行う。 In the above three-layer sheet, an adhesive is applied to both surfaces of the high-hardness urethane foam layer 2 and the low-hardness urethane sheet layer 3 is bonded to the surface. The applied adhesive penetrates into the urethane foam on the surface of each sheet. As the adhesive solidifies, the hardness of the portion where the adhesive is applied is further increased. The three-layer sheet 5 is introduced into the profile processing apparatus 8 to perform profile processing.
プロファイル加工装置８は、周囲に押圧杆９を突出させた対の押圧ロール１０，１０をニップ間隔１１を有して対峙させ、その間に三層シートを送り込むことで押圧ロール１０，１０のニップ間隙１１において三層シート５を対向する押圧ロール１０，１０の押圧杆９，９の間に押し込んでサインカーブ状に屈曲させた三層シート５を前記押圧ロール１０，１０の軸方向に設けたカッター１２によりカットする。カット後、押圧ロール１０，１０の回転につれ三層シート５がニップ間隙１１から出ると三層シート５の圧縮は解かれ、図１，図２に示すごとき、凸部６と凹部７とが交互に連続するクッション材１が、凹部７と凸部６とを対向させて送り出されて来る。対向する２枚のクッション材を分離して図１，２に示す状態とする。そして凹部７には厚さ方向にクッション材１を貫通して通気孔１５を設ける。 The profile processing device 8 causes a pair of pressing rolls 10 and 10 having a pressing bar 9 protruding around them to face each other with a nip interval 11, and a three-layer sheet is fed between them to feed a nip gap between the pressing rolls 10 and 10. 11 is a cutter in which the three-layer sheet 5 is pressed between the pressing rolls 9 and 9 of the pressing rolls 10 and 10 facing each other and bent in a sine curve shape in the axial direction of the pressing rolls 10 and 10. Cut by 12. After the cut, when the three-layer sheet 5 comes out of the nip gap 11 as the pressing rolls 10 and 10 are rotated, the compression of the three-layer sheet 5 is released, and as shown in FIGS. The cushion material 1 that is continuous is sent out with the concave portion 7 and the convex portion 6 facing each other. The two cushion materials facing each other are separated into the state shown in FIGS. The recess 7 is provided with a vent hole 15 that penetrates the cushion material 1 in the thickness direction.
上記のカッター１２による三層シートの切断により作られる凸部６は、基部１６と頂部１７とが低硬度ウレタンフォーム層３となり凸部６の中間部位は高硬度ウレタンアォーム層２となる。
また凸部６において、中間部位の材質が高硬度ウレタンフォーム層２に変化するが、その異なる材質のウレタンフォームは接着剤により接着されるので、該接着部位には固化した接着剤の層４が存在し凸部が就寝者を支え或は就寝者に指圧的効果を与えようとするときに凸部が座屈し或は妄動するようなことが無い。
In the convex portion 6 made by cutting the three-layer sheet by the cutter 12, the base portion 16 and the top portion 17 become the low-hardness urethane foam layer 3, and the intermediate portion of the convex portion 6 becomes the high-hardness urethane foam layer 2.
In the convex portion 6, the material of the intermediate portion changes to the high-hardness urethane foam layer 2. Since the urethane foam of the different material is bonded by an adhesive, the solidified adhesive layer 4 is formed at the bonded portion. When the convex portion exists and supports the sleeping person or tries to give the acupressure effect to the sleeping person, the convex portion does not buckle or relocate.
ウレタンフォームとして、通常硬度ウレタンフォームＲ（密度0.036g/cm3、硬度160N）、高硬度ウレタンフォームＧ（密度0.050g/cm3、硬度270N）、低硬度ウレタンフォームＦ（密度0.026g/cm3、硬度120N）の３種類を用い、厚さ８０ｍｍのプロファイル加工したクッション材を作成した。
本発明の、高硬度３層プロファイル品は、高硬度ウレタンフォームＧを通常硬度ウレタンフォームＲの間に挟んだ３層クッション材である。比較例１は、通常硬度ウレタンＲのみをプロファイル加工した単層クッション材、また、比較例２は、低硬度ウレタンＦを通常硬度ウレタンＲの間に挟んで作成した低硬度３層クッション材である。
As urethane foam, normal hardness urethane foam R (density 0.036g / cm 3 , hardness 160N), high hardness urethane foam G (density 0.050g / cm 3 , hardness 270N), low hardness urethane foam F (density 0.026g / cm 3) , And a hardness of 120 N), a cushioning material having a profile processing with a thickness of 80 mm was prepared.
The high-hardness three-layer profile product of the present invention is a three-layer cushion material in which a high-hardness urethane foam G is sandwiched between normal-hardness urethane foams R. Comparative Example 1 is a single-layer cushion material obtained by profiling only normal hardness urethane R, and Comparative Example 2 is a low-hardness three-layer cushion material created by sandwiching low-hardness urethane F between normal-hardness urethane R. .
本実施例と比較例とのクッション材圧縮時の荷重−歪み曲線を図４に示す。
図４は、本発明品をＪＩＳＫ６４００に基づき、２００ｍｍΦの円板でプロファイル表面から厚さ方向に５０ｍｍ／分の速度で圧縮したときの荷重−歪み曲線（以下；圧縮曲線という）を示す。図４において、曲線Ａは本発明の高硬度３層プロファイル品、曲線Ｂは比較例１（通常プロファイル品）、曲線Ｃは比較例２（低硬度３層プロファイル品）である。
本発明クッション材の圧縮曲線Ａはプロファイル凸部形状が圧縮される歪み１６ｍｍ近辺の荷重が比較例１（圧縮曲線Ｂ）、比較例２（圧縮曲線Ｃ）に比べて高い値を示していることがわかる。また、変形の大きい４８ｍｍ付近では圧縮曲線Ａの荷重は比較例の圧縮曲線Ｂ、圧縮曲線Ｃに比べ低いという特長がある。
FIG. 4 shows load-strain curves when the cushion material is compressed in this example and the comparative example.
FIG. 4 shows a load-strain curve (hereinafter referred to as a compression curve) when the product of the present invention is compressed with a disc of 200 mmΦ in a thickness direction from the profile surface at a speed of 50 mm / min based on JISK6400. In FIG. 4, curve A is a high hardness three-layer profile product of the present invention, curve B is Comparative Example 1 (normal profile product), and curve C is Comparative Example 2 (low hardness three-layer profile product).
The compression curve A of the cushion material of the present invention shows that the load near the strain 16 mm at which the profile convex shape is compressed is higher than that of Comparative Example 1 (compression curve B) and Comparative Example 2 (compression curve C). I understand. Further, there is a feature that the load of the compression curve A is lower than the compression curve B and the compression curve C of the comparative example in the vicinity of 48 mm where deformation is large.
表１に、本発明品と比較例品の物性を示す。
本発明のクッション材を圧縮したときの、圧縮し始めの低歪み領域（１６ｍｍ）とプロファイル凹凸部が完全に圧縮された高歪み領域（４０ｍｍ）の圧縮荷重を＜圧縮曲線＞の欄に示す。
＜圧縮曲線＞において、本発明のクッション材に荷重が掛かる際、沈み込み変形の小さい領域（低歪み領域）として１６ｍｍ圧縮時の荷重を見ると、本発明（高硬度３層プロファイル品）の値は比較例１（通常プロファイル品）比較例２（低硬度プロファイル品）よりも大きく、体にかかる体圧は大きいことが判る。低歪み領域は、プロファイルの凸部が変形する領域であり、指圧効果が高いことを示唆している。
一方、クッション材が大きく変形する高歪み領域として４０ｍｍ（マットレス厚さの５０％相当）まで圧縮したときの荷重を見ると、本発明の高硬度３層プロファイル品は低い値を示しており、大きく変形する腰部への負担は小さいことを示唆している。
Table 1 shows the physical properties of the product of the present invention and the comparative product.
When the cushion material of the present invention is compressed, the compression load of the low strain region (16 mm) at the start of compression and the high strain region (40 mm) in which the profile uneven part is completely compressed is shown in the <compression curve> column.
In <compression curve>, when a load is applied to the cushion material of the present invention, when the load at the time of 16 mm compression is viewed as a region where the subsidence deformation is small (low strain region), the value of the present invention (high hardness three-layer profile product) Is larger than Comparative Example 1 (normal profile product) and Comparative Example 2 (low hardness profile product), indicating that the body pressure applied to the body is large. The low distortion region is a region where the convex portion of the profile is deformed, suggesting that the acupressure effect is high.
On the other hand, when the load when compressed to 40 mm (corresponding to 50% of the mattress thickness) as a high strain region in which the cushion material greatly deforms is seen, the high hardness three-layer profile product of the present invention shows a low value. This suggests that the burden on the deformed waist is small.
本発明品、比較例１、比較例２のクッション材に、体重５５ｋｇ、身長１７０ｃｍの２６歳男子が仰臥位で寝たときのデータを、表１の＜体圧分散＞と＜沈みこみ量＞の欄に示す。体圧分散は、ＡＢＷ社製エルゴチェック機によるデータ、寝具の沈み込みデータは簡易型寝姿勢計測器（西川産業製；スパインフィッター・商標名）による計測値である。
本発明の高硬度３層プロファイル品は、ＭＡＸ体圧、平均体圧は比較例１（通常プロファイル品）よりも低く良好である。比較例２（低硬度３層プロファイル品）よりも体圧はやや高いが、腰部の沈み量、平均沈み量はこれよりも低く、本発明品は高硬度プロファイル部分で体圧が良好に分散されるためである。
また、＜圧縮残留歪み率＞は、クッション材を１６万回圧縮耐久性テストした後の値であり、通常のプロファイル品に比べ、残留歪み率は小さい。
表１のデータを総合的にみると、本発明の高硬度ウレタン３層プロファイル品はプロファイル凸部の指圧効果が高く、耐久性にも優れていることが判る。
The data obtained when a 26-year-old boy with a weight of 55 kg and a height of 170 cm slept on the cushion material of the present invention product, Comparative Example 1 and Comparative Example 2 were placed in the <body pressure dispersion> and <sink amount> in Table 1. It is shown in the column. The body pressure dispersion is measured by an ABW Ergocheck machine, and the bedding sinking data is measured by a simple sleeping posture measuring instrument (manufactured by Nishikawa Sangyo; Spinefitter, trade name).
The high hardness three-layer profile product of the present invention has a MAX body pressure and an average body pressure that are lower and better than Comparative Example 1 (normal profile product). Body pressure is slightly higher than Comparative Example 2 (low-hardness three-layer profile product), but the lowering of the waist and the average amount of sinking are lower than this, and the product of the present invention is well dispersed in the high-hardness profile part. Because.
Further, <compression residual strain ratio> is a value after the compression durability test of the cushion material 160,000 times, and the residual strain ratio is smaller than that of a normal profile product.
Looking at the data in Table 1 comprehensively, it can be seen that the high-hardness urethane three-layer profile product of the present invention has a high acupressure effect on the profile convex portion and is excellent in durability.
１ クッション材
２ 高硬度ウレタンフォーム層
３ 低硬度ウレタンフォーム層
４ 接着剤
５ 三層シート
６ 凸部
７ 凹部
８ プロファイル加工装置
９ 押圧杆
１０ 押圧ロール
１１ ニップ間隙
１２ カッター
１５ 通気孔
１６ 凸部６の基部
１７ 凸部６の頂部
DESCRIPTION OF SYMBOLS 1 Cushion material 2 High-hardness urethane foam layer 3 Low-hardness urethane foam layer 4 Adhesive 5 Three-layer sheet 6 Convex part 7 Concave part 8 Profile processing apparatus 9 Pressing rod 10 Press roll 11 Nip gap 12 Cutter 15 Ventilation hole 16 Convex part 6 Base 17 Top of convex part 6
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| JP6150481B2 (en) * | 2012-09-21 | 2017-06-21 | アキレス株式会社 | Cushion material |
| JP6338884B2 (en) * | 2014-02-26 | 2018-06-06 | 株式会社イノアックコーポレーション | Manufacturing method for clothing pad |
| JP6116498B2 (en) * | 2014-02-27 | 2017-04-19 | 昭和西川株式会社 | Mattress manufacturing method |
| JP6165799B2 (en) * | 2015-05-25 | 2017-07-19 | 株式会社ブリヂストン | Cushion material |
| JP6316366B2 (en) * | 2016-09-28 | 2018-04-25 | 昭和西川株式会社 | mattress |
| JP6989892B2 (en) * | 2017-10-02 | 2022-01-12 | 株式会社ブリヂストン | Cushion material |
| JP1638790S (en) * | 2018-10-01 | 2021-11-22 | ||
| JP7018378B2 (en) * | 2018-11-28 | 2022-02-10 | 株式会社ニトリホールディングス | mattress |
| JP7369397B2 (en) * | 2019-09-27 | 2023-10-26 | 西川株式会社 | Laminated cushion material |
| JP2021171487A (en) * | 2020-04-28 | 2021-11-01 | 株式会社ブリヂストン | Cushioning material, laminated cushioning material, and method of manufacturing cushioning material |
| CN114803153B (en) * | 2022-04-14 | 2024-01-12 | 联宝(合肥)电子科技有限公司 | Composite buffering packing material |
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| JPS54151716U (en) * | 1978-04-13 | 1979-10-22 | ||
| JPS55120813A (en) * | 1979-03-12 | 1980-09-17 | Mtp Kasei Kk | Production of cushion material with different hardness |
| JPS55171262U (en) * | 1979-05-28 | 1980-12-09 | ||
| JPS6048751U (en) * | 1983-09-07 | 1985-04-05 | 関口 栄四郎 | Cushion materials for seating, bedding, etc. |
| JP3168513B2 (en) * | 1997-01-31 | 2001-05-21 | アキレス株式会社 | Bedding mat |
| JP4043006B2 (en) * | 1998-12-11 | 2008-02-06 | アキレス株式会社 | Cushion material and manufacturing method thereof |
| JP2003061789A (en) * | 2001-08-27 | 2003-03-04 | Tomijiro Tokuda | Core of mattress |
| JP2007125099A (en) * | 2005-11-01 | 2007-05-24 | Toyo Tire & Rubber Co Ltd | Mattress cushion material and method of manufacturing the same |
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