JP6118781B2 - Cushion material - Google Patents

Description

  The present invention relates to a cushioning material suitable for materials such as seats and backrests of chairs and sofas, comforters, cushions, mattresses and mattresses.

  Conventionally, feather duvets have been used as materials for lightweight comforters that are both heat retaining and breathable. Downs (feathers) and feathers (feathers) are used for duvets, and those that have a large proportion of downs without feather shafts are generally regarded as luxury items. Feather is available as a low-cost material, but it is called a duvet when it is used alone or when the proportion of the feather exceeds 50%. It is distinguished from a duvet.

  In general, duvets are light and have high heat retention, so they are widely used as comforters. Also, because of the softness of the down, it may be used as a mattress material. On the other hand, since the feather is heavier and stiffer than the down, the duvet encapsulating the feather is used for the mattress. However, when a mattress is manufactured using a feather as an inclusion, it is hard and has a low body pressure dispersion function, so that the sleeping comfort is deteriorated. Furthermore, in a duvet using a feather with a curved blade axis, a rustling sound is generated when the futon is moved, and the softness is lacking.

  In recent years, foamed synthetic resins such as polyurethane resins and polyolefin resins have been used as mattress materials for low-resilience mattresses. A low-resilience mattress using such a synthetic foam resin is said to be effective in inhibiting blood flow and preventing floor rubbing because body pressure is dispersed throughout. On the other hand, it also has an aspect that air permeability is poor and heat generated from the body during sleep is difficult to escape. In addition, the mattress made of rug-like foamed synthetic resin often has a problem in that a specific part is often subjected to a load due to body pressure at the time of going to bed, so that deformation or settling is likely to occur in advance of only the specific part.

  In order to solve such disadvantages of the rug-like foamed synthetic resin, for example, in Patent Document 1, a foamed synthetic resin is made into small pieces, and a felt-like layer is disposed on both upper and lower sides of the core portion made of the small pieces, and the felt is further provided. A core material for bedding and the like has been proposed in which a sandwich-like laminate in which a surface layer made of a soft material such as cotton, wool, feathers or the like is disposed outside the layered layer is contained in a bag and quilted.

  Sure, if it is a bedding using a core material for bedding such as Patent Document 1, the foamed synthetic resin piece moves in the bag every time it is used, so it has excellent cushioning properties, such as sag and waist There is no deformation such as local dents or warping both ends upward, and air permeability is ensured.

  However, if the foamed synthetic resin pieces are simply packed in a bag, the movement of the small pieces within the bag will not cause deformation or settling at a specific location, but on the other hand, the small pieces generated during the movement within the bag Due to this friction, deformation and sag of each small piece occurs rapidly.

  In addition, when using a foamed synthetic resin piece, unlike a rug-like foamed synthetic resin, a jerky feeling occurs during use. For this reason, a complicated structure such as a sandwich-like laminate in which a felt-like layer and a surface layer made of a soft material are arranged as in the device of Patent Document 1 is necessary, which leads to an increase in cost. Furthermore, in the case of the structure of Patent Document 1, a new problem arises in that the felt-like layer having a rug shape is deformed or sag in a specific portion.

Japanese Patent Laid-Open No. 7-23835

  In view of the above situation, in the present invention, it is possible to make use of the heat retention and breathability of feathers and the low resilience characteristics of foamed synthetic resins by using inexpensively available feathers and foamed synthetic resin pieces. On the other hand, an object of the present invention is to provide a cushioning material that can suppress the rustling sound of the feather and the rapid sag of the foamed synthetic resin pieces.

In the present invention, a cushion material in which a feather and a foamable resin piece are encapsulated in a bag-like fabric, and the weight ratio between the foamable resin piece and the feather is foamed resin piece: feather. = 55: 45 to 70:30 is the main feature.

  According to the cushion material of the present invention, air permeability can be ensured by making it into small pieces while maintaining the low resilience which is the property of the foamable resin. In addition, deformation and settling do not occur in advance from a specific part. In addition, it is possible to secure heat retention in a light weight that is the nature of feathers.

  Furthermore, as a result of mixing the foamable resin pieces and the feathers, the foamable resin pieces get into the space between the feathers. The rugged feeling that occurs when a single resin piece is used alone and the rapid deformation and sag of each piece are also suppressed.

  Feather is originally a material with good air permeability, and even foamed resins that ensure air permeability by making small pieces do not impair the air permeability. For this reason, in an actual use scene, air moves every time you roll over, so that air permeability is promoted, and waste and sweat are volatilized, so it is always kept dry and very hygienic.

In addition, as a result of the demand for down-combination products for duvets, feathers as raw materials often become surplus. On the other hand, a foamable resin piece is generated as a piece when manufacturing a rug-like foamable resin. For this reason, at present, both the feather and the foamable resin piece are discarded in the normal production line. However, in the present invention without producing waste by reducing such a use by the material to be discarded as a raw material in the conventional production line Utame, material loss, the manufacturing costs also help to protect the environment (variable costs) Can be suppressed.

It is explanatory drawing which showed the structure of the cushioning material of this invention typically. It is a photograph of the vertical load testing machine used for the durability test. It is the photograph of the thermostat used for the temperature measurement for a breathability test. 2 is a photograph showing a result of temperature measurement obtained by temperature measurement in Example 1. FIG. It is a photograph which shows the mode of the body pressure dispersion | distribution measurement in a drape test. 2 is a photograph showing the results of body pressure dispersion measurement in Example 1. FIG.

(Bag-like fabric)
As schematically shown in FIG. 1, a bag-like fabric 1 used in the present invention is for enclosing a feather 2 and a foamable resin 3 in a mixed state therein. The fabric used for the bag-like fabric can be used without particular limitation as long as the inclusions do not jump out or leak out, but the down-proofed down used in feather duvets, among others. Proof cloth etc. can be used conveniently. Further, the fabric may be back-coated, and the fabric weight per unit area can be used without any limitation as long as the inclusion does not jump out or leak out. The bag-like fabric may have a single structure with a single cloth, or may have a multiple structure with a plurality of cloths.

(feather)
If the feather (feather) used by this invention is a feather generally used with a duvet or a duvet, it can be especially used without a restriction | limiting. Feathers from land birds and feathers from water birds can be used, as well as feathers from immature birds and feathers from mature birds. The size of the feather is not particularly limited, but a length from the root to the tip is preferably 30 mm to 60 mm.

  Moreover, it is general that the down which cannot be selected normally adheres to the feather, and even if the down is mixed in the present invention, there is no particular problem. However, if the ratio of down is larger than that of the feather, it is contrary to the purpose of providing a high-performance cushion material using the low-cost material that is the object of the present invention. In the same way as the standard called “duvet”, it means that the feather is present in excess of 50% with respect to the total weight of the feather and down.

(Foaming resin)
The foamable resin used in the present invention has a large number of bubbles (cells) dispersed in a resin matrix. There are no particular restrictions on the type of resin, but generally used as a cushioning material is a polyolefin resin or polyurethane resin. Of these, polyurethane resins are preferably used.

  The foamable resin used in the present invention is not a rug but a collection of small pieces. The shape and size of the small piece are not particularly limited. For example, in the case of a sphere or quadrilateral including an ellipse, a long diameter or a long side of about 20 mm to 40 mm is preferable. However, what can be used as the foamable resin piece of the present invention is not limited to a spherical shape or a quadrilateral shape, but may be an arbitrary shape such as a polygonal shape or a cylindrical body.

(Mixing ratio, relative length, etc.)
The feather and the foamed resin piece are sealed and mixed inside the bag-like fabric. The ratio of the feather and the foamed resin piece in the bag-like fabric is preferably in the range of foamable resin piece: feather = 55: 45 to 70:30. If you deviate from this range, a characteristic that a small percentage of the foamed resin pieces and feathers are inherently inherent, such as low resilience if foamable resin pieces, heat retention is sufficient if feathers are used. Otherwise, the synergistic effect of mixing them may be reduced.

The relative length of the foamable resin pieces relative to the length of the feather is the longest side of each foamable resin piece (polygon) when the average length from the root to the tip of each feather is 1. The average value of the longest diameter (in the case of a sphere) is preferably 0.3 to 0.7. If the relative length of the foamable resin is too short, it will enter the feather and tend to impair air permeability. On the other hand, when the relative length of the expandable resin is too long, it becomes easy to inhibit the recovery of the feather by Noke press feather. In the above definition, when the foamable resin piece has a cylindrical shape, for example, the longer one of the diameter and the tube length is adopted.

Hereinafter, the present invention will be described in more detail with reference to examples.
Example 1
As the polyurethane resin, Nitri Furniture Vietnam EPE urethane foam model number “M55” was used. This was made into small pieces by using the grinding function of Foam cutting machine “ESF007-2” manufactured by Shenzhen Xinqunli (China). The length of the longest side of each small piece was set within a range of 20 mm to 40 mm. The longest side average of each piece is 30 mm. As the feather, “WASHED GRAY DUCK FEATHER 4cm-6cm” manufactured by HANGZOU SAMSUNG DOWN PRODUCT CO.LTD was used. The average length from the root to the tip of each feather is 50 mm.

A bag of down proof fabric (made by WUJIANG CITY XINCHUN TEXTILE (China) Down Proof Fablic [75D / 36Fx160D / 288F / C]) with a weight ratio of 35:65 (feather: polyurethane resin piece) The mixture was encapsulated in a fabric. This was used as the cushioning material of Example 1. A photograph showing the state of the cushioning material used in Example 1 is shown in FIG.

(Comparative Example 1)
A cushioning material of Comparative Example 1 was prepared under the same conditions as in Example 1 except that only the feather was changed into the bag-like fabric.

(Comparative Example 2)
A cushioning material of Comparative Example 2 was prepared under the same conditions as in Example 1 except that only the polyurethane resin pieces were enclosed in the bag-like fabric.

(Comparative Example 3)
Comparative Example 3 was prepared under the same conditions as in Example 1, except that the bag-shaped fabric had a two-layer structure and a feather was sealed in the first layer and a small piece of polyurethane resin was sealed in the second layer. Cushion material. The enclosed amount of the feather and the polyurethane resin piece was set to a weight ratio of 35:65 (feather: polyurethane resin piece).

The cushion materials of Examples and Comparative Examples were tested according to “Test Standard: JIS S 1102: 2004 Mattress Performance and Measurement Test Durability Test”.
Test content: Vertical load tester HAIDA INTERNATIONAL's "HD-1086-T Mattress Edge Durability Tester" (see photo in Fig. 2), load of 1000N on the mattress at 160 ± 10 times / min. To do.
The determination of durability is made based on whether or not the following conditions a) to d) are satisfied.
・ Acceptance conditions for mattress durability
a) Sag amount is 40mm or less (the position where the pressure sensor felt 5N is 0, and the difference between before and after the test is seen)
b) No slippage, fraying or tearing
c) No stuffing movement, depression or detachment
d) bending of the spring, there is no etc. outside Rena

(Test 2: Breathability test)
Judgment of air permeability was performed by a moisture diffusibility test using a thermostatic chamber.
Using the HAIDA INTERNATIONAL company (China) temperature chamber Midway Chamber “HD-E702-150B” shown in the photograph of FIG. 3, the cushioning material of the example and the comparative example was put and the inside of the temperature chamber was set to 40 ° C. Place in a room temperature environment of 27 degrees after 4 hours. The temperature of the cushion materials of Examples and Comparative Examples is measured after 5 minutes using a Thermal Camera [i7] manufactured by FLIR. The temperature measurement result is obtained as a temperature distribution image as shown in FIG. The numerical value of the temperature is displayed at the upper left corner of the temperature distribution image.

(Test 3: Drapability test)
Drapability was judged by comparing data before and after the durability test of the contact area using the body pressure test.
As shown in the photograph of FIG. 5, using a MESTEC (Taiwan) body pressure dispersion measuring machine “Bedding fit”, a male with a height of 172 cm and a body weight of 62 kg was used as a test subject. Compare the difference of numerical values in the Support Area [cm ² ] before and after the test. The Support Area indicates an area where the body is in close contact with the pressure sensor of the body pressure dispersion measuring machine. The softer the surface, the higher this number, and the mattress is along the body surface. As shown in FIG. 6, the numerical value of Support Area [cm ² ] is calculated from the body pressure dispersion measurement result image and displayed at the upper left corner of the image.

(Evaluation)
The results obtained in tests 1 to 3 are summarized in Table 1. For Test 1, in addition to the pass / fail judgment for each of the Examples and Comparative Examples, specific numerical values obtained in the test for the amount of sag are also shown.

In test 1 (endurance test), in the case of comparative example 2 (urethane piece only), the amount of sag was large and the test failed. This is biased by impact in the back of the urethane package,
This is because no repulsion can be obtained in the sensor section.

In the case of Comparative Example 1 (feather only) in Test 3 (drape test), there is no change in the drapeability before and after the test, but the support area is smaller than that of the example in the first place, and the surface becomes a hard mattress.
In the case of Comparative Example 2 (urethane piece only), the Support Area is larger after the test. This is because the sag occurred in urethane in Test 1, and the load portion was dented and the contact area increased, and the drapability was not improved. When the drooping occurs, the sleeping posture is lost, so that the sleeping comfort becomes worse during actual use.
In the case of Comparative Example 3 (separated enclosure of feather and urethane), the Support Area is larger after the test as in Comparative Example 2. This is because the sag occurred in urethane in Test 1, and the load portion was dented and the contact area increased, and the drapability was not improved. When the settling occurs, the sleeping posture is lost during actual use, which makes the sleeping comfort worse.

  As described above, the cushion material of the present invention is excellent in breathability and durability due to use while maintaining the heat retention property of the feather and the low resilience property of the foamable resin, and the defect that the feather is inherent and the foamable resin. This is an economical and high-value-added material that can be used for seats and backrests of chairs and sofas, comforters, cushions, mattresses, mattresses, etc. Is extremely large.

DESCRIPTION OF SYMBOLS 1 Bag-like fabric 2 Feather 3 Foaming resin piece

Claims (7)

A cushion material in which a feather and a foamable resin piece are enclosed in a mixed state in a bag-like fabric ,
The cushioning material characterized by the weight ratio of the said foaming resin piece and the said feather being in the range of foaming resin piece: feather = 55: 45-70: 30 . The average length of the longest side or diameter or major axis of each of the foamed resin pieces when the average length from the root to the tip of each of the feathers is 1, is 0.3 to 0.7. Cushion material. The chair containing the structure of the cushion material of the said Claim 1 or 2. The sofa containing the structure of the cushioning material of the said Claim 1 or 2. A mattress comprising the configuration of the cushion material according to claim 1. A comforter including the cushion material according to claim 1. A cushion comprising the cushion material according to claim 1.