JP6951130B2 - Cushion material and bedding - Google Patents

Description

The present invention relates to cushions material and bedding. For more information, bedding, cushions, cushions material that can be used as the core in such as rugs, on the bedding with the cushions material as the corrugated medium as well.

Conventionally, a futon such as a mattress is formed by covering the core with a bag-shaped cloth or a cotton mattress. Polyester solid cotton is generally used as the core, but when compression is repeated, the curl of the polyester solid cotton gradually extends and the elasticity decreases, and the thickness of the polyester solid cotton during long-term use. There is a risk that so-called "sagging" will occur. In addition, since polyester solid cotton has a high apparent density, the weight of the entire futon becomes heavy, and there is also a problem that the labor burden of raising and lowering the futon every day is heavy.

Therefore, Patent Document 1 proposes a laminate that suppresses the occurrence of sagging and can be used as a lightweight core. This laminate has a sheet-like first foam having ventilation holes and shape retention, and a net-like soft second foam disposed on at least one surface of the first foam. The average size of the net of the second foam is smaller than that of the ventilation holes of the first foam. Since the first foam has ventilation holes and the second foam is formed in a net shape, the weight of the laminated body can be reduced, and the second foam is the first. Since the foam is reinforced, the settling of the laminated body is reduced.

Japanese Unexamined Patent Publication No. 2006-142000

In the laminated body disclosed in Patent Document 1, the sheet-shaped first foam and the net-shaped second foam are laminated in multiple layers and then sewn with a sewing machine to integrate them to prevent the shape from being lost. However, when trying to sew a sheet-like first foam and a net-like second foam in multiple layers for sewing, the first foam and the second foam Due to the torque sent out in the sewing direction, the first foam and the second foam stacked in multiple layers are displaced from each other, and it is difficult to sew in a neatly stacked state, and the shape is likely to be lost. Further, when the laminate in which the first foam and the second foam are displaced from each other is pushed into the cloth bag, the surface of the futon may be uneven, and the appearance may be deteriorated and the commercial value may be impaired. ..

The present invention has been made in view of the above points, and an object of the present invention is to provide a cushioning material and bedding that have little settling and do not easily lose their shape.

The cushioning material according to one aspect of the present invention includes a shaping material as a core and an elastic material attached to the outside of the shaping material in a floating state. The shaping material is a plate-shaped polyurethane foam having protrusions and recesses on its surface. The elastic material is a polyethylene-based foam having a plurality of linear bodies intersecting to form a tubular shape or a bag shape, having a foaming ratio of 15 to 80 times, and an average cell diameter of 0.3 to 1.5 mm. It is formed.

The elastic member is preferably a nets.

The net is preferably intersection before Symbol plurality of linear body is thermally fused.

The bedding according to one aspect of the present invention is
A cover is provided on the outside of the cushion material.

In the present invention, since the tubular or bag-shaped elastic material is movably attached to the outside of the shaping material, the elastic material can be supported by the shaping material, and the elastic material and the shaping material are mutually supported. It can move to relieve stress, has less settling, and does not easily lose its shape.

FIG. 1 is a perspective view showing an embodiment of a cushioning material according to the present invention. FIG. 2 is a plan view showing a part of the elastic material according to the present invention. FIG. 3 is a perspective view showing another embodiment of the cushion material according to the present invention. FIG. 4A is a perspective view showing an embodiment of the bedding according to the present invention. FIG. 4B is a cross-sectional view showing an embodiment of the bedding according to the present invention. FIG. 5 is a perspective view showing another embodiment of the bedding according to the present invention.

Hereinafter, modes for carrying out the present invention will be described.

FIG. 1 shows the cushion material 1 of the present embodiment. The cushion material 1 is formed by including the elastic material 11 and the shaping material 12.

[Elastic material 11]
The elastic material 11 is for ensuring the cushioning property of the cushion material 1. Since the elastic material 11 has elasticity, its shape and volume change due to an external force, but when the external force is removed, it recovers to its original state again and has shape retention.

The elastic material 11 is preferably formed of a resin foam as a material. As the resin foam, any of hard or soft or a combination of hard and soft can be used, but it is preferable that the resin foam is soft in consideration of ease of attachment to the shaping material 12. Further, the cell structure of the resin foam may be a closed cell structure, an open cell structure, or a mixture of closed cells and open cells.

As the resin foam, various synthetic resin foams can be used, and a copolymer foam obtained by polymerizing two or more kinds of monomers may be used. Specifically, examples of the resin foam include polyolefin-based foams such as polyurethane-based foams, polystyrene-based foams, polyethylene-based foams, and polypropylene-based foams. Among these, the elastic material 11 is preferably formed of a polyethylene-based foam, whereby the elastic material 11 has high durability against repeated compression and can reduce settling. Examples of the ethylene-based resin for forming the polyethylene-based foam include polyethylene [for example, low, medium or high-density polyethylene resin, linear low-density polyethylene resin], and a polyethylene-based polymer [for example, ethylene-propylene co-weight. Combined, ethylene-butene-1 copolymer, ethylene-propylene-butene-1 copolymer, ethylene- (4-methylpentene-1) copolymer, etc.], copolymer of ethylene and vinyl monomer [ Ethylene-vinyl acetate copolymer, ethylene- (meth) acrylic acid copolymer or metal salt thereof, ethylene- (meth) acrylic acid C1-4 alkyl ester copolymer (ethylene-methyl methacrylic acid copolymer, etc.) Etc.] can be exemplified.

The expansion ratio of the resin foam forming the elastic material 11 is 15 to 80 times, preferably 20 to 50 times. The average cell diameter of the resin foam forming the elastic material 11 is 0.3 to 1.5 mm, preferably 0.4 to 1.5 mm, and more preferably 0.5 to 1.3 mm. The cross section of the bubble is not limited to a circular shape but may be an elliptical shape or the like. In the case of a foam having a closed cell structure, the closed cell ratio can be in the range of 60 to 100%, preferably 70 to 100%, and more preferably 80 to 100%. In the case of a foam having an open cell structure, the open cell ratio can be in the range of 50 to 100%, preferably 70 to 100%, and more preferably 90 to 100%.

The elastic material 11 is formed in a tubular shape or a bag shape. When the elastic material 11 is formed in a cylindrical shape, both ends of the elastic material 11 are open, and when the elastic material 11 is formed in a bag shape, one end of the elastic material 11 is open and the other end is open. The end is closed. The cross-sectional shape of the elastic material 11 (cross-sectional shape in the direction parallel to the opening) is formed in a circle, an ellipse, or the like, but it may be formed in accordance with the shape of the shaping material 12.

As shown in FIG. 2, the elastic material 11 is preferably formed of a net, which allows the elastic material 11 to be ventilated through the mesh 14 and has air permeability. The net constituting the elastic material 11 is formed by overlapping and intersecting a plurality of linear bodies 13. When the linear bodies 13 are overlapped and crossed in this way, the surface of the elastic material 11 has irregularities. Therefore, the elastic material 11 is less likely to come into close contact with the surface of the shaping material 12, and the air permeability of the cushion material 1 is less likely to be impaired.

The intersecting angle of the intersecting linear bodies 13 is not particularly limited and may be 90 °, but the internal angle of the mesh 14 in the major axis direction is 10 to 60 °, preferably 15 to 50 °, and further. It can be preferably 20 to 45 °. Further, among the crossing angles of the linear bodies 13, the internal angle of the mesh in the minor axis direction can be 100 to 170 °, preferably 120 to 170 °, and more preferably 130 to 170 °.

The linear body 13 is formed of the resin foam as described above, and is particularly preferably formed of the polyethylene-based foam as described above from the viewpoint of durability. In this case, the plurality of linear bodies 13 are joined by heat fusion or the like at the intersecting portions to form a net. The elastic material 11 is formed to be stretchable by the elasticity of the linear body 13 and the expansion and contraction of the mesh 14 of the net.

The average width of the linear body 13 is, for example, 2 to 10 mm, preferably 3 to 8 mm, more preferably 3 to 7 mm, and the distance between the intersecting portions of the linear body 13 is, for example, in the major axis direction. , 10 to 100 mm, preferably 15 to 70 mm, more preferably 20 to 50 mm, and in the minor axis direction, for example, 3 to 30 mm, preferably 5 to 25 mm, still more preferably 7 to 20 mm. Can be done.

Further, the shape of the mesh 14 of the net of the elastic material 11 is formed in a diamond shape, and the inner diameter of the mesh 14 in the major axis direction may be, for example, 5 to 60 mm, preferably 10 to 40 mm, and more preferably 10 to 20 mm. The inner diameter of the mesh 14 in the minor axis direction can be, for example, 5 to 30 mm, preferably 10 to 20 mm, and more preferably 15 to 20 mm.

Further, in the elastic material 11, the mesh 14 may be formed regularly or irregularly. Further, the spacing and the extending direction of the linear bodies 13 may be regular or irregular. The cross-sectional shape of the linear body 13 may be, for example, a circular shape, an ellipsoidal shape, a spindle shape, a polygonal shape (triangle, quadrangle, hexagonal shape, etc.), a flat shape, a plate shape, or the like. The average diameter (outer diameter) of the linear body 13 can be 4 to 50 mm, preferably 5 to 40 mm, and more preferably 6 to 30 mm.

[Excipient 12]
The shaping material 12 is a core material (core material) of the cushion material 1, which substantially forms (shapes) the entire cushion material 1 and also has an action of supporting the elastic material 11. The shaping material 12 preferably has elasticity, and in this case, the shaping material 12 also has shape retention.

The shaping material 12 is formed of a resin foam, a fiber aggregate, or the like as a material. As the resin foam, any combination of hard or soft or hard and soft can be used. Further, the cell structure of the resin foam may be a closed cell structure, an open cell structure, or a mixture of closed cells and open cells. As the resin foam, various synthetic resin foams can be used, and a copolymer foam obtained by polymerizing two or more kinds of monomers may be used. Specifically, examples of the resin foam include polyolefin-based foams such as polyurethane-based foams, polystyrene-based foams, polyethylene-based foams, and polypropylene-based foams. Further, the fiber aggregate is formed by joining a large number of synthetic fibers by heat fusion or the like and integrating them, and examples of the synthetic fibers include polyethylene fibers and polypropylene fibers.

The shaping material 12 is formed in a sheet shape or a plate shape, but is not limited to this, and can be formed in any shape. For example, the shaping material 12 can be formed on a flat plate having a flat surface. Further, the shaping material 12 may have a large number of convex portions and concave portions on the surface and have high cushioning property and tactile sensation. Further, the shaping material 12 may have a large number of through holes penetrating in the thickness direction and have air permeability.

The material and form (size, thickness, surface shape, etc.) of the excipient 12 are appropriately selected according to the purpose of use of the cushioning material 1 in consideration of sagging property, cushioning property, flexibility, breathability, and the like. Be selected. For example, the shaping material 12 can be formed by appropriately combining different or similar resin foams, and in this case, different or similar resin foams can be formed by laminating two or more layers.

The shaping material 12 shown in FIG. 1 is a plate material formed of a polyurethane-based foam, and a large number of convex portions 121 and concave portions 122 are formed over the entire surface of the plate material. The excipient 12 shown in FIG. 3 is made of two different materials. One is a fiber assembly 123 in which a large number of polypropylene fibers are joined by heat fusion and integrated. The other one is formed of a net cylinder 124. The net cylinder 124 is formed of a polyethylene-based foam, and a large number of linear bodies intersect to form a net cylinder. As the net cylinder 124, the same elastic material 11 as the elastic material 11 can be used.

[Cushion material 1]
The cushion material 1 is formed by mounting the elastic material 11 on the outside of the shaping material 12. That is, in the cushion material 1, the shaping material 12 is arranged inside the elastic material 11 having a tubular shape or a bag shape. Since the elastic material 11 is attached to the outside of the shaping material 12 in this way, the cushion material 1 is less likely to be settled. Further, the external force or load applied to the elastic material 11 can be supported by the shaping material 11, and the elasticity of the elastic material 1 is less likely to decrease.

When the elastic material 11 is attached to the outside of the shaping material 12, the shaping material 12 can be inserted into the elastic material 11 through the opening of the tubular or bag-shaped elastic material 11. After this insertion, the shaping material 12 and the elastic material 11 are not fixed, and the shaping material 12 and the elastic material 11 are in a state where they can move almost freely with each other. That is, the elastic material 11 is loosely attached with a gap so as not to be in close contact with the outer surface of the shaping material 12, and the elastic material 11 and the shaping material 12 are formed so as to be playable. Therefore, the elastic material 11 and the shaping material 12 move with each other, and it is difficult to fix their positions with each other. As a result, even when an external force or load is applied to the cushion material 1, the elastic material 11 and the shaping material 12 can move with each other to relieve stress, and the elastic material 11 and the shaping material 12 are distorted. Is less likely to occur and the cushion material 1 is less likely to lose its shape.

The thickness of the cushion material 1 can be appropriately set depending on the application and the like, but can be selected from the range of, for example, 10 to 150 mm, and may be 20 to 70 mm, preferably 30 to 70 mm.

[bedding]
The bedding 2 of the present embodiment includes the cushion material 1 as a core, and is formed by including the cushion material 1 and a cover 15 that covers the cushion material 1. Examples of the bedding 2 include, but are not limited to, pillows 21 as shown in FIGS. 4A and 4B, mattresses 22 as shown in FIG. 5, and the like. Examples of the cover 15 include fabrics and nets, but the cover 15 is not limited thereto. The cover 15 is provided so as to cover the entire outer surface of the elastic material 11, but a part of the outer surface of the elastic material 11 may be covered with the cover 15. Further, the plurality of cushioning materials 1 may be covered with one cover 15.

Since the cushion material 1 is covered with the cover 15 in the bedding 2, the design of the bedding 2 can be improved and the feeling of use such as touch can be improved. Further, since the cushion material 1 is less likely to lose its shape, it is less likely to be deformed even after long-term use, and the deterioration of the appearance of the bedding 2 can be reduced.

In the bedding 2 of the present embodiment, the cover 15 and the shaping material 12 may be combined. As described above, since the elastic body 11 and the shaping material 12 are not fixed, the shaping material 12 moves with respect to the elastic body 11, but the shaping material 12 is soft and the elastic body 11 On the other hand, if it is slippery (for example, when it contains a silicone-based compound), the excipient 12 may shrink due to its own weight or an external force and may be biased inside the elastic body 11.

Therefore, it is possible to combine the cover 15 and the shaping material 12 to make the shaping material 12 less likely to shrink and to make it less likely to be biased. When joining the cover 15 and the shaping material 12, the shaping material 12 is formed so that the end portion of the shaping material 12 protrudes from the opening of the tubular or bag-shaped elastic material 11 by about several centimeters, and the shape material 12 is elastic. The end of the shaping material 12 protruding from the opening of the material 11 and the cover 15 are joined. In this way, even if the shaping material 12 tries to shrink, the cover 15 is caught by the opening edge of the elastic material 11, and the shrinkage of the shaping material 12 can be supported by the rigidity of the elastic material 11, and the shaping material can be supported. 12 is less likely to be biased. In this case, the elastic material 11 is less likely to be deformed than the shaping material 12, and has rigidity that can withstand the force of the shaping material 12 to shrink.

Since the elastic material and the cushion material according to the present invention are excellent in breathability, cushioning property, durability and the like, they can be effectively used for bedding such as mattresses, pillows and mattresses, cushions and sofas.

1 Cushion material 11 Elastic material 12 Excipient material 13 Striatum 15 Cover 2 Bedding

Claims (4)

A cushioning material including a core shaping material and an elastic material that is mounted on the outside of the shaping material in a floating state.
The shaping material is a plate-shaped polyurethane-based foam, which has convex portions and concave portions on its surface.
The elastic material is a polyethylene-based foam having a plurality of linear bodies intersecting to form a tubular shape or a bag shape, having a foaming ratio of 15 to 80 times, and an average cell diameter of 0.3 to 1.5 mm. It is formed,
Cushion material . The elastic material is a net.
The cushion material according to claim 1 . The net intersection before Symbol plurality of linear bodies are thermally fused,
The cushion material according to claim 2. A cover is provided on the outside of the cushion material according to any one of claims 1 to 3.
Bedding .

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