JP7270533B2 - Cushion body manufacturing method, manufacturing apparatus, and cushion body - Google Patents

Description

The present invention relates to a cushion body manufacturing method, a manufacturing apparatus, and a cushion body.

2. Description of the Related Art Conventionally, cushion bodies (cushion bodies that support upper users) used for mattresses, sofa cushions, etc. have been widely used. As such a cushion body, for example, as disclosed in Patent Document 1 and Patent Document 2, a filament three-dimensionally bonded body (three-dimensional net-like structure) obtained by three-dimensionally fusion-bonding filaments made of a thermoplastic resin is known. structure).

According to Patent Document 1, after a molten polyethylene resin is extruded vertically downward from a plurality of horizontally arranged nozzles, a molten filament with a diameter of about 1 mm is dropped into cooling water and melted by the buoyancy of the water. It is disclosed that a filament loop is formed and at the same time, a plurality of molten filaments are three-dimensionally fusion-bonded to produce a highly airy filament three-dimensional bonded body with a porosity exceeding 90%. there is

WO2017/122370 JP 2010-154965 A

Cushion bodies used in mattresses and the like generally have a lower repulsive force to give a user a soft feeling of use, and also have the effect of preventing the occurrence of pressure ulcers as much as possible, for example, for bedridden patients. can be expected. However, if the overall repulsive force of the cushion body is too low, the body will hit the floor or the like under the cushion body, or a state close to this, and there is a risk of causing a feeling of hitting the bottom or inducing bedsores. .

In consideration of this point, the cushion body has a lower repulsive force in the upper part (the part closer to the user) and a relatively higher repulsive force in the lower part, thereby maintaining a soft feeling of use as much as possible. can suppress the feeling of hitting the bottom, and is also effective in preventing pressure ulcers. It is desired that the cushion body be formed so as to have an appropriate repulsive force for the user.

SUMMARY OF THE INVENTION An object of the present invention is to provide a manufacturing method that enables easy manufacture of a cushion body having an appropriate repulsive force for the user.

A manufacturing method according to the present invention is a manufacturing method for manufacturing a cushion body that supports a user on the upper side by deforming an intermediate body, wherein the intermediate body includes a first low-resilience layer and a first low-resilience layer. A first high resilience layer that is contiguous with the resilience layer and has a higher repulsion than the first low resilience layer, a second low resilience layer, and a second low resilience layer that is contiguous with the second low resilience layer and has a higher repulsion than the second low resilience layer. 2 high resilience layers, and these are a filament three-dimensional combination arranged in the layer direction in the order of the first high resilience layer, the first low resilience layer, the second low resilience layer, and the second high resilience layer. At least one of the first low-resilience layer and the second low-resilience layer is exposed upward as an upper layer, and at least one of the first high-resilience layer and the second high-resilience layer is exposed under the upper layer. is arranged as a lower layer, and the method is a process of deforming the intermediate body.

According to this manufacturing method, it is possible to easily manufacture a cushion body having an appropriate repulsive force for the user. Further, in the manufacturing method described above, the deformation processing is performed by moving at least a portion of the facing portion upward from the intermediate body in which a portion between the first low-resilience layer and the second low-resilience layer is separated and faces each other. It is good also as a method which is a process exposed to. In addition, the "upper side" in relation to the cushion body in the present application merely indicates the side that supports the user (the side closer to the user) for the sake of convenience.

Further, in the above manufacturing method, the deformation processing involves bending the intermediate body so that the first high-resilience layer and the second high-resilience layer face each other, and one of the first low-resilience layer and the second low-resilience layer faces upward. A method of exposing and exposing the other downward may be used.

Further, in the above manufacturing method, the intermediate body is provided with a high resilience layer having a higher repulsion force than the low resilience layer so as to cover the entire outer periphery of the low resilience layer when viewed in a predetermined direction orthogonal to the layer direction. Alternatively, the low resilience layer may include a first low resilience layer and a second low resilience layer, and the high resilience layer may include a first high resilience layer and a second high resilience layer.

Further, a manufacturing apparatus according to the present invention is a manufacturing apparatus for manufacturing the intermediate used in the above manufacturing method, and includes a molten filament supply unit that discharges the molten filament group vertically downward, and a molten filament group that cools the molten filament group. and a fusion bond forming part for forming a three-dimensional filament assembly by fusion bonding the filaments, wherein the fusion bond formation part is in contact with the entire peripheral portion of the outer edge of the discharged molten filament group when viewed from below. , and may be configured to have a receiving portion for guiding the portion to the center side.

Further, in the above configuration, the molten filament supply part has a nozzle part formed with a plurality of openings for discharging the molten filament group, and the nozzle part does not have the openings in the central region. A configuration having a non-ejection region may also be employed.

Further, the manufacturing apparatus according to the present invention is a cushion body that supports the user on the upper side, and is formed by a filament three-dimensional combination in which a low-resilience layer and a high-resilience layer having a higher repulsion force than the low-resilience layer are connected to each other. and the high resilience layer may be arranged under the low resilience layer exposed upward.

Further, in the above configuration, the filament three-dimensional combination includes a first low-resilience layer, a first high-resilience layer connected to the first low-resilience layer and having a higher repulsion than the first low-resilience layer, and a second low-resilience layer. and a second high resilience layer contiguous to the second low resilience layer and having a higher resilience than the second low resilience layer, one of the first low resilience layer and the second low resilience layer facing upward, The other may be exposed downward, and the first high-resilience layer and the second high-resilience layer may be arranged between the first low-resilience layer and the second low-resilience layer.

According to the manufacturing method of the present invention, it is possible to easily manufacture a cushion body having an appropriate repulsive force for the user.

1 is a conceptual diagram of a manufacturing apparatus for a three-dimensional filament assembly; FIG. 2 is a cross-sectional view taken along the line A-A' shown in FIG. 1; FIG. FIG. 4 is a perspective view showing one configuration example of a receiving portion; It is the bottom view which looked at an example of the nozzle part from the downward direction. FIG. 10 is an explanatory diagram relating to an example in which a cavity forming member is provided; It is a perspective view which shows an example of an intermediate. It is a figure which shows the state which cut into the intermediate body. 1 is a side view showing a first embodiment of a cushion body; FIG. FIG. 5 is a side view showing a second embodiment of a cushion body; It is a side view which shows 3rd Embodiment of a cushion body. It is a schematic side sectional view showing one example of composition of a mattress.

An embodiment of the present invention will be described below with reference to the drawings.

1. Apparatus and Method for Manufacturing Intermediate Body As will be described later, the cushion body according to the present invention is manufactured by deforming the intermediate body. The device will be explained. The manufacturing apparatus is an apparatus for manufacturing a filament three-dimensionally bonded body, which is an intermediate.

FIG. 1 is a conceptual diagram of an apparatus 1 for manufacturing a three-dimensionally bonded filament according to one embodiment of the present invention. 2 is a cross-sectional view taken along line A-A' shown in FIG. 1. As shown in FIG. The vertical, horizontal, and front/rear directions (directions perpendicular to each other) in the description of the manufacturing apparatus 1 are as shown in the respective drawings. These directions are merely determined for the sake of convenience such that the vertical direction is the up-down direction, and the facing direction of a pair of receiving plates 30 described later is the front-rear direction.

The apparatus 1 for manufacturing a three-dimensional filament assembly includes a molten filament supply unit 10 for vertically downwardly discharging a molten filament group MF composed of a plurality of molten filaments having a diameter of 0.5 mm to 3 mm, and a molten filament group MF which is three-dimensionally fed. A fusion bonding forming section 20 is provided for forming a filament three-dimensionally bonded body 3DF by cooling and solidifying the filaments after the filaments are physically entangled to fusion bond the contact points.

The molten filament supply section 10 includes a pressurized melting section 11 (extruder) and a filament discharge section 12 (die). The pressure melting section 11 includes a material charging section 13 (hopper), a screw 14, a screw motor 15 for driving the screw 14, a screw heater 16, and a plurality of temperature sensors (not shown). A cylinder 11 a is formed inside the pressurization melting section 11 for transporting the thermoplastic resin supplied from the material charging section 13 while heating and melting it with a screw heater 16 .

A screw 14 is rotatably accommodated in the cylinder 11a. A cylinder discharge port 11b for discharging the thermoplastic resin toward the filament discharge portion 12 is formed at the downstream end of the cylinder 11a. The heating temperature of the screw heater 16 is controlled based on a detection signal from a temperature sensor provided in the molten filament supply section 10, for example.

The filament discharge part 12 includes a nozzle part 17, a die heater 18, and a plurality of temperature sensors (not shown), and has a guide path 12a for guiding the molten thermoplastic resin discharged from the cylinder discharge port 11b to the nozzle part 17. formed.

The nozzle part 17 is a substantially rectangular parallelepiped metal thick plate with a plurality of openings, and is provided below the filament discharge part 12, which is the most downstream part of the guide path 12a. Note that the plurality of openings formed in the nozzle portion 17 will be described later with reference to FIG. 4 .

A plurality of die heaters 18 (six in the example shown in FIG. 2) are provided in the left-right direction, and heat the filament discharge section 12 . The heating temperature of the die heater 18 is controlled based on a detection signal from a temperature sensor provided in the filament discharge section 12, for example.

Thermoplastic resins that can be used as materials for the three-dimensional filament assembly include, for example, polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, polyamide resins such as nylon 66, polyvinyl chloride resins, and polystyrene. Resins, thermoplastic elastomers such as styrene-based elastomers, vinyl chloride-based elastomers, olefin-based elastomers, urethane-based elastomers, polyester-based elastomers, nitrile-based elastomers, polyamide-based elastomers, and fluorine-based elastomers can be used.

The thermoplastic resin supplied from the material input portion 13 is heated and melted in the cylinder 11a, and extruded by, for example, the screw 14 to form a melted thermoplastic resin, which is introduced from the cylinder discharge port 11b into the guide path 12a of the filament discharge portion 12. supplied to After that, a molten filament group MF composed of a plurality of molten filaments is discharged from each of the plurality of nozzles (openings) of the nozzle portion 17 so as to translate downward.

The fusion bond forming section 20 includes a cooling water tank 23 , a pair of conveyors 24 , a plurality of transport rollers 25 a - 25 h and a receiving section 300 . The receiving part 300 includes a first receiving plate 31 and a second receiving plate 32 . The first receiving plate 31 (the receiving plate 30 on the front side) and the second receiving plate 32 (the receiving plate 30 on the rear side) are provided as a pair of front and back receiving plates 30, and the thickness of the filament three-dimensional combination 3DF is regulated. At the same time, it plays a role of forming a high resilience layer on this.

The cooling water tank 23 is a water tank for storing the cooling water W. Inside the cooling water tank 23, a pair of conveyors 24 and a plurality of conveying rollers 25a to 25h are arranged. A pair of conveyors 24a, 24b and a plurality of conveying rollers 25a to 25h are driven by a driving motor (not shown).

FIG. 3 is a schematic perspective view of the receiving part 300. FIG. The receiving part 300 has a first receiving plate 31 , a second receiving plate 32 , a third receiving plate 33 , a first side plate 34 , a fourth receiving plate 35 and a second side plate 36 .

The first receiving plate 31 is a metal plate having bent portions including a flat plate-like inclined portion 31A that slopes downward toward the rear and a flat plate-like vertical portion 31B that extends downward in the vertical direction from the lower end of the inclined surface 31A. be. The second receiving plate 32 is a metal plate having a bent portion including a flat plate-like inclined portion 32A that slopes downward toward the front and a flat plate-like vertical portion 32B that extends downward in the vertical direction from the lower end of the inclined portion 32A. be. These vertical portions 31B and 32B are parallel to each other and face each other in the front-rear direction.

The third receiving plate 33 is a metal plate fixed to the left ends of the inclined portions 31A and 32A by welding or the like, and has a flat plate shape that slopes down toward the right. The first side plate 34 is a metal plate fixed to the left ends of the vertical portions 31B and 32B and the lower end of the third receiving plate 33 by welding or the like.

The fourth receiving plate 35 is a metal plate fixed to the right ends of the inclined portions 31A and 32A by welding or the like, and has a flat plate shape that slopes down toward the left. The second side plate 36 is a metal plate fixed to the right ends of the vertical portions 31B and 32B and the lower end of the fourth receiving plate 35 by welding or the like. The vertical portions 31B, 32B, the first side plate 34, and the second side plate 36 form a cuboid cylindrical portion 300A.

FIG. 4 is a bottom view of the nozzle portion 17 viewed from below. The nozzle portion 17 is formed with a plurality of openings 171 through which the molten filament group is discharged. The openings 171 are arranged in the left-right direction to form one row, and the one row is arranged in the front-rear direction to form a zigzag arrangement as a whole. The cross-sectional shape of the opening 171 is, for example, a circle with an inner diameter of 1 mm. It should be noted that the number of openings 171, arrangement form, and the like shown in FIG. 4 are merely examples.

A projection area 17A indicated by a dotted line in FIG. 4 is an inlet 3001 ( That is, it is an area obtained by upwardly projecting the upper end opening of the cylindrical portion 300A. The molten filament discharged downward from the opening 171 located outside the projection area 17A in FIG. It is guided to the input port 3001 . That is, the receiving portion 300 contacts the entire peripheral portion of the outer edge of the molten filament group MF discharged from the nozzle portion 17 and guides the portion toward the center. As a result, the filaments are denser in the vicinity of the outer edge of the molten filament group MF when viewed from below, and the portion of the intermediate body corresponding to this region (corresponding to the high resilience layer 5B described later) is correspondingly higher. It will have a repulsive force.

The molten filament discharged downward from the opening 171 positioned inside the projection area 17A in FIG. The part of the molten filament group MF near the center when viewed from below is hardly affected by the contact of the molten filament group MF with the receiving part 300, and the intermediate body part corresponding to this area (corresponding to the low-resilience layer 5A described later) ) has a lower repulsive force than the high resilience layer 5B.

A non-ejection region 17B indicated by another dotted line in FIG. 4 is a central partial region (central region of the nozzle portion 17) within the projection region 17A, and an opening 171 in the non-emission region 17B is plugged by a plug member. and the molten filament cannot be discharged. It should be noted that the opening 171 may not be provided in the non-discharge region 17B to prevent the molten filament from being discharged. Thus, the nozzle portion 17 has a non-ejection region 17B in which the formation of the opening 171 is omitted in the central region. Therefore, the portion of the intermediate body corresponding to this region is in a state of being hollow (corresponding to a through hole 51 described later) or having a small amount of filament and being easily cut. Note that the ranges of the projected area 17A and the non-ejection area 17B shown in FIG. 4 are only examples, and the molten filament may also be emitted from the central area of the nozzle section 17 without setting the non-ejection area 17B according to various circumstances. It does not matter if it is discharged.

Further, in order to ensure that the above cavity is formed, a substantially plate-shaped cavity forming member 38 may be provided below the non-ejection region 17B as illustrated in FIG. 4A. The cavity forming member 38 illustrated in FIG. 4A is arranged inside the receiving portion 300 and formed slightly larger in the front-rear direction than the non-ejection region 17B.

An upper portion of the cavity forming member 38 is formed with a slope that slopes downward from the center in the front-rear direction toward the outer side, and the molten filament that strikes the cavity forming member 38 from above advances downward by sliding along the slope. Therefore, the molten filament group MF discharged from the nozzle portion 17 is guided inward in the front-rear direction (toward the center) at the portions corresponding to the inclined portions 31A and 32A as indicated by the colored arrows in FIG. It is possible to guide the portion corresponding to the contact outward in the front-rear direction as indicated by the white arrow in this figure.

When the cavity forming member 38 is provided in this manner, the cavity can be formed without providing the non-ejection region 17B. Also, if the amount of molten filaments hitting the upper portion of the cavity forming member 38 is increased, the amount of molten filaments guided as indicated by the white arrows in FIG. can be done. In this way, the repulsive force near the surface of the cavity (the repulsive force near the surface formed in contact with the cavity forming member 38) is greater than the repulsive force near the surface formed in contact with the receiving portion 300. It is also possible to make it higher. In this case, it is possible to obtain a cushion body having a layer with a high repulsive force inside without performing a process for turning over the intermediate body, which will be described later.

The molten filament cluster MF discharged from the nozzle portion 17 advances to the cooling water tank 23 via the receiving portion 300, and is bent by the buoyancy action of the cooling water W in the cooling water tank 23 to form random loops. The random loops are three-dimensionally fused with adjacent random loops, and the points of contact are fusion bonded to form a three-dimensional filament assembly.

After that, the combined body is transported while being cooled by the cooling water W in the cooling water tank 23 by the conveyor 24 and the plurality of transport rollers 25a to 25h, and discharged out of the cooling water tank 23 as the three-dimensional filament combined body 3DF. be. By cutting the filament three-dimensionally bonded body 3DF continuously formed in the conveying direction in this way at every predetermined length, an intermediate to be described later is obtained.

2. Configuration of Intermediate Next, the configuration of the intermediate 5 manufactured by the manufacturing apparatus 1 described above will be described. FIG. 5 is a perspective view showing an example of the intermediate 5. As shown in FIG. FIG. 5 also shows a specific direction (corresponding to the “predetermined direction” according to the present invention) orthogonal to the vertical direction and the horizontal direction, and this specific direction is the filament three-dimensional combination that is the basis of the intermediate 5 It is the same as the transport direction at the time of manufacture for 3DF.

As shown in FIG. 5, the intermediate body 5 consists of a low-resilience layer 5A and a high-resilience layer 5B. The low-resilience layer 5A is formed with an annular surface extending in a specific direction. The high resilience layer 5B has a higher repulsion force than the low resilience layer 5B, and is formed by extending in a specific direction an annular surface that covers the outer circumference of the annular surface of the low resilience layer 5A. The low-resilience layer 5A has through-holes 51 extending inward in a specific direction. When viewed from one of the specific directions, the intermediate body 5 has a dimension in the horizontal direction larger than that in the vertical direction, and the through holes 51 extend in the horizontal direction.

The portion of the high resilience layer 5B (first high resilience layer H1) in the upper portion of the intermediate body 5 corresponds to the first high resilience layer according to the present invention, and the low resilience layer 5A connected to the lower side thereof corresponds to the first high resilience layer. The portion (first low-resilience layer L1) corresponds to the first low-resilience layer according to the present invention. On the other hand, the portion of the high resilience layer 5B (second high resilience layer H2) in the lower portion of the intermediate body 5 corresponds to the second high resilience layer according to the present invention, and the low resilience layer 5A connected to the upper side thereof corresponds to the second high resilience layer of the present invention. The portion (second low-resilience layer L2) corresponds to the second low-resilience layer according to the present invention. Therefore, the intermediate body 5 is a filament in which these layers are arranged in the layer direction (vertical direction) in order of the first high resilience layer H1, the first low resilience layer L1, the second low resilience layer L2, and the second high resilience layer H2. It corresponds to a three-dimensional combination.

Further, since the molten filament is not discharged from the non-discharging region 17B of the nozzle portion 17 described above, the intermediate body 5 is formed with a through hole 51 (gap). Even if the through-hole 51 is not formed in the intermediate body 5 at first, by making a cut or the like instead of the through-hole 51 in the vicinity of the center of the low-resilience layer 5A, a through-hole 51 is formed. can do.

For example, an intermediate body in which the receiving part 300 shown in FIG. may be manufactured. Even in this case, in the intermediate body, the first high-resilience layer H1, the first low-resilience layer L1, the second low-resilience layer L2, and the second high-resilience layer H2 are arranged in this order in the layer direction (vertical direction). It corresponds to a filament three-dimensional combination.

3. Manufacture of Cushion Body A cushion body is manufactured by deforming the intermediate body 5 having the above-described structure. Here, a method for manufacturing the cushion body will be described.

7A and 7B schematically show a first embodiment of a cushion body manufactured by deforming the intermediate body 5. FIG. In FIG. 7, the cushion body 61 is viewed in a specific direction perpendicular to the vertical direction and the horizontal direction. This specific direction is a direction perpendicular to the paper surface, and the same applies to FIGS. 8 and 9 described later.

In order to manufacture the cushion body 61, a cut C is made in the intermediate body 5 as shown in FIG. The notch C is a cut surface formed by extending in a specific direction a line segment extending from the left end of the through hole 51 (or a notch or the like that replaces the through hole 51) to the outer edge of the high resilience layer 5B. If the through-hole 51 is not formed in the intermediate body 5 , the cut instead of the through-hole 51 and the cut C described above may be provided in the intermediate body 5 at the same time.

The cushion body 61 shown in FIG. 7 is manufactured by folding the upper portion of the cut C to the right by 180° while the cut C is inserted into the intermediate body 5 . As a result, the cushion body 61 has the high resilience layer 5B extending in the left-right direction and the low resilience layer 5A extending in the left-right direction and arranged above the high resilience layer 5B. In other words, the deformation process applied to the intermediate body 5 is a process of deforming the intermediate body 5 so that the high resilience layer 5B is disposed under the low resilience layer 5A exposed upward. In addition, the entire wall surface of the through hole 51 of the intermediate body 5 (or the notch or the like that replaces the through hole 51) is exposed upward as the upper surface of the low-resilience layer 5A of the cushion body 61. FIG.

FIG. 8 is a diagram schematically showing a second embodiment of a cushion body manufactured by deforming the intermediate body 5. As shown in FIG. The cushion body 62 shown in FIG. 8 is manufactured by folding the upper portion of the cut C to the right by 360° with the cut C inserted into the intermediate body 5 (see FIG. 6). That is, the cushion body 62 is obtained by folding the right portion of the cushion body 61 shown in FIG. 7 further downward.

As a result, the cushion body 62 has a configuration in which the U-shaped low-resilience layer 5A is disposed around the outer periphery of the U-shaped high-resilience layer 5B when viewed in a specific direction, and the second low-resilience layer is arranged in order from the top. L2, the second high resilience layer H2, the first high resilience layer H1, and the first low resilience layer L1 are laminated. That is, the deformation processing performed to manufacture the cushion body 62 for the intermediate body 5 is to make the upper and lower high resilience layers 5B face each other, and the wall surface of the through hole 51 (or a notch or the like instead of the through hole 51). It is a process of exposing a part upward and exposing another part of the wall surface downward.

FIG. 9 is a diagram schematically showing a third embodiment of a cushion body manufactured by deforming the intermediate body 5. FIG. The cushion body 63 shown in FIG. 9 is manufactured without providing the cut C as shown in FIG.

That is, the cushion body 63 is manufactured by turning over the intermediate body 5 so that the outer peripheral surface and the inner peripheral surface of the intermediate body 5 in the state shown in FIG. 5 are exchanged. As a result, the cushion body 63 has a structure in which the ring-shaped low-resilience layer 5A is arranged around the ring-shaped high-resilience layer 5B when viewed from a specific direction. The cushion body 63 has a through hole 631 extending in a specific direction.

As in the case of the cushion body 62, the deformation processing for manufacturing the cushion body 63 on the intermediate body 5 is also performed by making the upper and lower high resilience layers 5B face each other and forming the through holes 51 (or instead of the through holes 51). It is a process that exposes a part of the wall surface such as a cut in the wall upward and exposes another part of the wall surface downward.

As for the mode of use of the cushion body of each embodiment shown in FIGS. A person is supported by the cushion body. At this time, in the cushion bodies 61 to 63, the high resilience layer 5B is arranged under the low resilience layer 5A exposed upward. In this way, while the repulsive force of the upper portion of the cushion body (the portion close to the user) is low, the repulsive force of the lower side is relatively high, thereby maintaining the soft feeling of use as much as possible while maintaining the bottom. It can suppress the piercing feeling and is effective in preventing pressure ulcers. That is, the cushion body of each embodiment is formed so as to have an appropriate repulsive force for the user.

Therefore, for example, when the cushion body is used for a bed mattress, it is possible to eliminate the feeling of hitting the bottom while suppressing pressure ulcers of the user supported by the mattress. The cushion bodies 61 to 63 can be used, for example, as cushions for sofas, pillows, floor cushions, etc., in addition to mattresses.

In particular, with regard to the cushion bodies 62 and 63 (see FIGS. 8 and 9) of the second or third embodiment, the high resilience layer is placed under the low resilience layer exposed upward even if the upside down is reversed. is arranged. Therefore, it can be reversible so that it can be used in the same way even if it is turned upside down. It can be used cleanly with the side surface facing upward.

Note that FIG. 10 is a diagram schematically showing an example of a mattress manufactured using the cushion body 62 (see FIG. 8) according to the second embodiment. A mattress 7 shown in FIG. 10 is formed by arranging a plurality of cushion bodies 62 . More specifically, each cushion body 62 is wrapped with a cover 71 made of cloth or the like and arranged. Accordingly, it is possible to change the number of cushion bodies 62 arranged according to the height of the user P supported by the mattress 7 . A mattress may be configured by wrapping a plurality of cushion bodies 62 in a single cover 71 .

Moreover, it is a matter of course that the cushion bodies 61 and 63 according to the first and third embodiments may be arranged to form the mattress 7 . As described above, various products such as mattresses can be manufactured using the cushion body according to the present embodiment.

4. Others As described above, the manufacturing method for manufacturing the cushion body according to each embodiment is a method for manufacturing the cushion body that supports the user on the upper side by deforming the intermediate body 5 . In addition, the intermediate body 5 includes a first low-resilience layer L1, a first high-resilience layer H1 connected to the first low-resilience layer L1 and having a higher repulsion than the first low-resilience layer L1, and a second low-resilience layer L2, and a second high resilience layer H2 connected to the second low resilience layer L2 and having a higher resilience than the second low resilience layer L2. These are the first high resilience layer H1 and the first low resilience layer. A filament three-dimensional combination in which L1, a second low-resilience layer L2, and a second high-resilience layer H2 are arranged in this order in the layer direction. Furthermore, the deformation process exposes at least one of the first low-resilience layer L1 and the second low-resilience layer L2 upward as an upper layer, and the first high-resilience layer H1 and the second high-resilience layer H1 and the second high-resilience layer under the upper layer. This is a process of transforming the intermediate body 5 into a state in which at least one of H2 is arranged as a lower layer.

According to the manufacturing method, it is possible to easily manufacture a cushion body having an appropriate repulsive force for the user. That is, it is not easy to obtain a filament three-dimensionally combined body in which a low-resilience layer is provided on the outer peripheral side and a high-resilience layer is connected to the inner side of the low-resilience layer. On the other hand, for the three-dimensional filament assembly having a high resilience layer on the outer peripheral side and a low resilience layer connected to the inner side of the high resilience layer like the intermediate body of the present embodiment, as already described, the manufacturing apparatus provided with the receiving part 300, for example, 1 and obtaining such intermediates is relatively easy.

Therefore, according to the method of manufacturing the cushion body according to the present embodiment, the cushion body having an appropriate repulsive force for the user, that is, the upper part (closer to the It is possible to manufacture a cushion body in which the repulsive force of the lower portion is relatively high while the repulsive force of the lower portion is low. In addition, since the first low-resilience layer L1 and the first high-resilience layer H1 are connected to each other (not like joining layers that were originally separate but continuously connected), these layers There is no risk of separation between them, and there is no sense of incongruity due to a large change in material characteristics at these boundaries. This point also applies to the second low-resilience layer L2 and the second high-resilience layer H2.

More specifically, the deformation processing is such that a part of the first low-resilience layer L1 and the second low-resilience layer L2 are separated and opposed to each other (that is, the through holes 51 or cuts instead thereof are formed. The processing is such that at least a part of the facing portion is exposed upward with respect to the intermediate body 5 (opposing via). Therefore, it is possible to easily form the cushion bodies of the first to third embodiments. The deformation process for forming the cushion body of the second embodiment is performed by bending the intermediate body 5 so that the first high resilience layer H1 and the second high resilience layer H2 are opposed to each other, and forming the first low resilience layer L1. and the second low-resilience layer L2 are exposed upward and the other downward.

In addition, the intermediate 5 of the present embodiment has a high repulsion force higher than that of the low resilience layer 5A so as to cover the entire outer periphery of the low resilience layer 5A when viewed in a specific direction (predetermined direction orthogonal to the layer direction). A layer 5B is provided. Furthermore, the low-resilience layer 5A includes a first low-resilience layer L1 and a second low-resilience layer L2, and the high-resilience layer 5B includes a first high-resilience layer H1 and a second high-resilience layer H2. Therefore, in the high resilience layer 5B, the first high resilience layer H1 and the second high resilience layer H2 are provided without interruption. It is possible to have a continuous configuration up to

Although the embodiments of the present invention have been described above, the configuration of the present invention is not limited to the above embodiments, and various modifications can be made without departing from the gist of the invention. That is, the above-described embodiments should be considered as examples in all respects and not restrictive. The technical scope of the present invention is defined by the scope of claims rather than the description of the above embodiments, and is understood to include all modifications within the scope and meaning equivalent to the scope of claims. should.

INDUSTRIAL APPLICABILITY The present invention can be used, for example, for manufacturing cushion bodies used for mattresses, cushions for sofas, and the like.

1 Apparatus for manufacturing a three-dimensional filament assembly 10 Melted filament supply section 11 Pressure melting section 11a Cylinder 11b Cylinder discharge port 12 Filament discharge section 12a Guide channel 13 Material input section 14 Screw 15 Screw motor 16 Screw heater 17 Nozzle section 17A Projection Area 17B Non-ejection area 171 Opening 18 Die heater 20 Fusion bond forming part 23 Cooling water tank 24 Conveyor 25a to 25h Conveyor roller 300 Receiving part 31 First receiving plate 32 Second receiving plate 33 Third receiving plate 34 First side plate 35 fourth receiving plate 36 second side plate 38 cavity forming member 5 intermediate body 5A low resilience layer 5B high resilience layer 51 through holes 61 to 63 cushion body 631 through hole 7 mattress 71 cover 100 cushion body 101 cushion body cover 101A, 101B Opening 105 Cushion body with cover 106 Bag body 106A Insertion port 110 Mattress C Notch

Claims (4)

A manufacturing method for manufacturing a cushion body that supports a user on the upper side by deforming the intermediate body,
The intermediate is
a first low-resilience layer, a first high-resilience layer connected to the first low-resilience layer and having a higher repulsion than the first low-resilience layer, a second low-resilience layer, and a second low-resilience layer connected to the second low-resilience layer and a second high resilience layer having a higher resilience than the low resilience layer, which are arranged in the layer direction in the order of the first high resilience layer, the first low resilience layer, the second low resilience layer, and the second high resilience layer. A three-dimensional conjugate of arranged filaments,
The deformation processing is
At least one of the first low-resilience layer and the second low-resilience layer is exposed upward as an upper layer, and at least one of the first high-resilience layer and the second high-resilience layer is arranged as a lower layer under the upper layer. A manufacturing method characterized by a process of deforming the intermediate body to a state in which the intermediate body is deformed. The deformation processing is
For the intermediate body in which a part between the first low-resilience layer and the second low-resilience layer is separated and opposed to each other, the processing is such that at least a part of the opposed part is exposed upward. The manufacturing method according to claim 1. The deformation processing is
The intermediate body is bent so that the first high resilience layer and the second high resilience layer are opposed to each other, and one of the first low resilience layer and the second low resilience layer is exposed upward and the other is exposed downward. 3. The manufacturing method according to claim 2, characterized in that: The intermediate is
A high resilience layer having a higher repulsion force than the low resilience layer is provided so as to cover the entire outer periphery of the low resilience layer when viewed in a predetermined direction orthogonal to the layer direction,
The low-resilience layer comprises a first low-resilience layer and a second low-resilience layer, and the high-resilience layer comprises a first high-resilience layer and a second high-resilience layer. The manufacturing method according to any one of the above.

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