JP7504937B2 - Mattress and manufacturing method thereof - Google Patents

Description

The present invention relates to a mattress and a method for manufacturing the same.

Conventionally, adjustable bed devices are known that are equipped with auxiliary functions such as back-raising and knee-raising functions so that users such as the elderly and physically disabled can easily change their posture on the bed device. A mattress is placed on the floor plate surface of such adjustable bed devices. For example, Patent Document 1 discloses a mattress holding system for adjustable beds.

Patent No. 6013371

There is a demand for mattresses that can be folded according to the user's posture, such as mattresses for adjustable bed devices. Even the mattress disclosed in the above-mentioned Patent Document 1 has room for improvement in terms of its foldability.

Therefore, one of the objectives of the present invention is to provide a mattress that can be folded in accordance with the user's posture and a method for manufacturing the same.

A mattress according to one embodiment of the present invention comprises a spring unit, and a wall member surrounding the spring unit having a first portion formed of foam and a second portion formed of a foam softer than the foam forming the first portion, wherein the wall member has a plurality of first regions formed of the first portion , and a second region formed of the first portion and the second portion stacked in the thickness direction of the spring unit, positioned between the plurality of first regions, and softer than the first regions.

The first portion in the second region may be connected to the first portions in the plurality of first regions.

The spring unit may be formed in a substantially rectangular parallelepiped shape, and the wall member may have a pair of side walls sandwiching the spring unit in at least one of the longitudinal direction and the width direction of the spring unit, and the pair of side walls may each have the plurality of the first regions and the second region. The second region of one of the pair of side walls may face the second region of the other of the pair of side walls. The pair of side walls may each have a plurality of the second regions arranged at intervals. The spring unit may have a frame line provided on a peripheral portion. The peripheral portion may have a portion where the frame line is not provided between the second region of the one of the pair of side walls and the second region of the other of the pair of side walls. The mattress may further include a cushioning material arranged between the wall member and the spring unit in the longitudinal direction. The cushioning material may be located between the second regions in the width direction.

A method for manufacturing a mattress according to one aspect of the present invention includes the steps of placing a laminate including the spring unit on a workbench, providing a frame surrounding the side periphery of the laminate placed on the workbench, and forming the wall member between the side periphery and the frame.

The present invention provides a mattress that can be folded in response to the user's posture, and a method for manufacturing the same.

FIG. 1 is a schematic perspective view of a mattress according to one embodiment. FIG. 2 is a schematic perspective view of an inner body provided in the mattress. FIG. 3 is a schematic plan view of an inner body of the mattress. FIG. 4 is a schematic side view of the inner body of the mattress. FIG. 5 is a schematic cross-sectional view of an inner body provided in the mattress. FIG. 6 is a schematic partial enlarged view of portion VI shown in FIG. 7A-7D are schematic cross-sectional views illustrating the steps involved in forming the wall member. FIG. 8 is a schematic enlarged partial view of the workbench shown in FIG.

One embodiment will be described with reference to the drawings. In this embodiment, a mattress placed in an adjustable bed device is disclosed as an example of a mattress.

In the following description, the "upper surface" of each element constituting the mattress refers to the surface that faces the side on which a person sits when the mattress is in use, and the "lower surface" of each element refers to the surface that faces the floor when the mattress is in use. Additionally, the "side peripheral surface," "outer peripheral surface," and "inner peripheral surface" of each element refer to the surfaces that connect the upper and lower surfaces.

Figure 1 is a schematic perspective view of a mattress 1 according to this embodiment. As shown in the figure, an X direction, a Y direction, and a Z direction that are mutually perpendicular are defined. The X direction corresponds to the width direction of the mattress 1. The Y direction corresponds to the longitudinal direction of the mattress 1. The Z direction corresponds to the thickness direction of the mattress 1 (the direction from the lower surface to the upper surface of the mattress 1). The length along the thickness direction is sometimes referred to as the thickness.

Viewing the mattress 1 parallel to the Z direction is called a plan view. One end of the mattress 1 in the Y direction may be called the head side, and the other end may be called the foot side. The Y direction is, for example, the direction from the head side to the foot side of the mattress 1.

The mattress 1 according to this embodiment is formed in a substantially rectangular parallelepiped shape. In a plan view, the mattress 1 is substantially rectangular with short sides along the X direction and long sides along the Y direction. The four corners of the mattress 1 may be smoothly curved.

The mattress 1 comprises an exterior body 2 and an interior body 3 disposed inside the exterior body 2. The exterior body 2 is formed, for example, from a cloth material. The exterior body 2 may be, for example, quilted.

Next, the structure of the inner body 3 will be described with reference to FIGS.
Fig. 2 is a schematic perspective view of the inner body 3 included in the mattress 1. The inner body 3 has an upper surface 31, a lower surface 32, an end portion 33 located on the head side, and an end portion 34 located on the foot side. In the example shown in Fig. 2, the inner body 3 is formed in a substantially rectangular parallelepiped shape. In a plan view, the inner body 3 is substantially rectangular with short sides along the X direction and long sides along the Y direction.

Figure 3 is a schematic plan view of the inner body 3 included in the mattress 1. Figure 4 is a schematic side view of the inner body 3 included in the mattress 1. Figure 5 is a schematic cross-sectional view of the inner body 3 included in the mattress 1. Figure 6 is a schematic partial enlarged view of part VI shown in Figure 5.

In Fig. 3, a part of the inner body 3 is shown in cross section. In Fig. 4, the inner body 3 is viewed parallel to the X direction. As shown in Figs. 3 to 6, the inner body 3 includes a spring unit 4, protective materials 5A and 5B, cushioning materials 6A and 6B, a head-side cushioning material 7, head-side protective materials 8A and 8B, and a wall member 10.

The spring unit 4 is formed in a substantially rectangular parallelepiped shape. The width direction of the spring unit 4 corresponds to the X direction, the longitudinal direction of the spring unit 4 corresponds to the Y direction, and the thickness direction of the spring unit 4 corresponds to the Z direction.

The spring unit 4 has a plurality of spring bodies 41. The plurality of spring bodies 41 are arranged in the X direction. The spring body 41 has a plurality of coil portions 42, each of which is made of a single wire such as a steel wire, and whose axes are substantially parallel and spaced apart at a predetermined interval.

The multiple spring bodies 41 are connected by multiple helical wires 43 arranged along the X direction. The helical wires 43 are arranged at predetermined intervals in the Y direction. The helical wires 43 are wound around the upper and lower ends of the coil portions 42 of adjacent spring bodies 41, respectively. In this way, the adjacent spring bodies 41 are connected in the X direction.

The spring unit 4 further has a number of frame lines 44 connected to the spring body 41. The frame lines 44 are provided on the periphery of the top and bottom surfaces of the spring unit 4. On the periphery of the top surface of the spring unit 4, the frame lines 44 are provided at the ends 33 and 34, respectively.

At the periphery of the underside of the spring unit 4, frame lines 44 are provided at the ends 33 and 34. At the periphery, frame lines 44 are provided on the entire portion along the X direction, the corners, and the portion along the Y direction.

The periphery of the spring unit 4 in the Y direction has a portion where the frame line 44 is provided and a portion where the frame line 44 is not provided. In the example shown in FIG. 3, the portion where the frame line 44 is not provided is larger than the portion where the frame line 44 is provided.

The frame line 44 is connected to the spring body 41 by a number of clips 45. At the ends 33 and 34, the clips 45 are provided along the X direction. In the example shown in FIG. 3, one end of the frame line 44 is bent toward the center of the spring unit 4 in the X direction.

The frame 44 is formed in a tube shape from a synthetic resin such as polyethylene. As another example, the frame 44 can be formed from a hard material such as steel or hard synthetic resin.

As shown in FIG. 5, protective material 5A is disposed on the upper surface side of spring unit 4, and protective material 5B is disposed on the lower surface side of spring unit 4. Protective materials 5A and 5B can be formed of, for example, felt, sisal, or compressed cotton. The thicknesses of protective materials 5A and 5B are, for example, equal.

Cushion material 6A is disposed on the upper surface side of protective material 5A, and cushion material 6B is disposed on the lower surface side of protective material 5B. Cushion materials 6A and 6B can be formed of a foam such as urethane foam. As an example, the specific gravity of urethane foam is 0.025. The thicknesses of cushion materials 6A and 6B are, for example, equal.

The head-side cushion material 7 and the head-side protective materials 8A and 8B are provided on the end 33 side. The head-side cushion material 7 is disposed closer to the end 33 side than the spring unit 4. From another perspective, in the Y direction, the head-side cushion material 7 is located between the wall member 10 and the spring unit 4.

The head-side cushion material 7 can be made of a foam such as urethane foam. As an example, the specific gravity of urethane foam is 0.025. The head-side cushion material 7 is connected to the spring unit 4 by, for example, tape 20 (shown in FIG. 3). The tape 20 can be made of, for example, nonwoven fabric.

The head-side protective material 8A is disposed on the upper surface side of the cushion material 6A, the head-side cushion material 7, and the wall member 10, and the head-side protective material 8B is disposed on the lower surface side of the cushion material 6B, the head-side cushion material 7, and the wall member 10. In the thickness direction, the head-side protective materials 8A and 8B overlap the cushion materials 6A and 6B, the head-side cushion material 7, and the wall member 10.

The head side protective materials 8A and 8B can be made of, for example, felt, sisal, or compressed cotton. The thicknesses of the head side protective materials 8A and 8B are, for example, equal. The head side protective materials 8A and 8B are harder than, for example, the cushioning materials 6A and 6B and the head side cushioning material 7.

The head-side cushion material 7 and the head-side protection materials 8A and 8B correspond to the position of a bed plate that constitutes a head-lifting mechanism (head-up mechanism) in an adjustable bed device, for example. The bed plate is supported by the head-side protection material 8B, preventing the bed plate from digging into the cushion material 6B and the head-side cushion material 7.

The interior body 3 further includes a sheet member 9. The sheet member 9 is located, for example, between the wall member 10 and the spring unit 4. FIG. 3 shows the sheet member 9 located between the wall member 10 and the spring unit 4 in the X direction. The sheet member 9 can be formed, for example, from a foam such as urethane foam.

The wall member 10 is formed in a frame shape. The wall member 10 surrounds the side surfaces of the spring unit 4, the protective materials 5A and 5B, the cushioning materials 6A and 6B, the head-side protective materials 8A and 8B, and the head-side cushioning material 7. The wall member 10 has an inner peripheral surface 11 on the spring unit 4 side, and an outer peripheral surface 12 on the opposite side to the inner peripheral surface 11.

The wall member 10 has a pair of side walls 13, 14 aligned in the X direction, and a pair of side walls 15, 16 aligned in the Y direction. In the Y direction, the side wall 15 is located on the head side, and the side wall 16 is located on the foot side.

In the example shown in FIG. 3, the four corners of the wall member 10 formed by the pair of side walls 13, 14 and the pair of side walls 15, 16 are formed at approximately 90 degrees, but may be formed into smooth curved surfaces.

The pair of side walls 13, 14 sandwich the spring unit 4 in the X direction, and the pair of side walls 15, 16 sandwich the spring unit 4 in the Y direction. The cross-sectional shape of the side walls 13, 14 along the X direction is approximately rectangular, and the cross-sectional shape of the side walls 15, 16 along the Y direction is approximately rectangular.

The wall member 10 has a first portion P1 formed of a foam and a second portion P2 formed of a foam that is softer than the foam forming the first portion P1. The first portion P1 and the second portion P2 can be formed of a foam such as urethane foam. The first portion P1 is a relatively hard foam. The hardness of the foam forming the second portion P2 is less than the hardness of the foam forming the first portion P1.

In the example shown in FIG. 3, the side walls 13 and 14 are provided with a plurality of second portions P2. The side walls 13 and 14 are formed by the first portion P1 and a plurality of second portions P2, and the side walls 15 and 16 are formed by the first portion P1.

For ease of explanation, the second portion P2 is indicated by a dot in FIG. 4. In the example shown in FIG. 4, when the side wall 14 is viewed parallel to the X direction, the shape of the second portion P2 is substantially rectangular.

In the side walls 13 and 14, the multiple second portions P2 include, from the end portion 33 side, a second portion P21, a second portion P22, and a second portion P23. In the X direction, the second portion P21 of the side wall 13 faces the second portion P21 of the side wall 14, the second portion P22 of the side wall 13 faces the second portion P22 of the side wall 14, and the second portion P23 of the side wall 13 faces the second portion P23 of the side wall 14.

In the X direction, the second portion P21 of the side wall 13 and the second portion P21 of the side wall 14 sandwich the head-side cushion material 7 and the spring unit 4. The second portions P22, P23 of the side wall 13 and the second portions P22, P23 of the side wall 14 sandwich the spring unit 4. As shown in FIG. 3, in the X direction, the frame line 44 is not located between the second portions P22, P23 of the side wall 13 and the second portions P22, P23 of the side wall 14.

In the side walls 13 and 14, the length of the first portion P1 in the X direction is approximately equal to the length of the second portion P2 in the X direction. In the side walls 13 and 14, the inner peripheral surface 11 and the outer peripheral surface 12 are formed by the first portion P1 and the multiple second portions P2.

The lengths of the multiple second portions P2 in the Y direction are, for example, equal to each other. In the example shown in FIG. 3, the length of the second portion P21 in the Y direction is smaller than the length of the head-side protective material 8A in the Y direction. In the example shown in FIG. 4, the length L2 of the second portion P2 in the Z direction is smaller than the overall length L10 of the side wall 14 in the Z direction.

The sidewall 14 has a first region A1 and a second region A2 that is softer than the first region A1. The first portion P1 is located in the first region A1, and the first portion P1 and the second portion P2 are located in the second region A2.

A second area A2 is formed in the sidewall 14 according to the position of the second portion P2. The second area A2 is softer than the first area A1 because it includes the second portion P2 formed of a soft foam.

In the side wall 14, the first area A1 and the second area A2 are aligned in the Y direction. In the side wall 14, a plurality of second areas A2 are formed and aligned at intervals. From another perspective, the second area A2 is located between two first areas A1 aligned in the Y direction.

In the second region A2, the length L2 of the second portion P2 in the Z direction is smaller than the entire length of the second region A2 in the Z direction. In the second region A2 shown in FIG. 4, the first portion P1 overlaps the second portion P2.

From another perspective, in the second region A2, the first portion P1 is located above the second portion P2. The first portion P1 of the second region A2 is connected to the first portion P1 of the first region A1.

The length of the second portion P2 in the Y direction corresponds to the length of the second region A2 in the Y direction. Focusing on the second region A2, the length L2 of the second portion P2 in the Z direction is smaller than the length L1 of the first portion P1 in the Z direction.

The length L2 of the second portion P2 in the Z direction may be greater than or equal to the length L1 of the first portion P1 in the Z direction. The sum of the length L1 of the first portion P1 and the length L2 of the second portion P2 corresponds to the length L10 of the side wall 14.

As described above, the second region A2 is softer than the first region A1. From another perspective, the second region A2 is easier to bend in the Z direction and in the direction opposite the Z direction than the first region A1.

Similar to side wall 14, side wall 13 also has a first area A1 and a second area A2. In the X direction, the second area A2 of side wall 13 and the second area A2 of side wall 14 sandwich the spring unit 4 and the like. Therefore, the inner body 3 can be easily folded around an axis along the X direction at the position where the second areas A2 of side walls 13 and 14 are formed.

The mattress 1 according to this embodiment has multiple areas that are easy to fold. The adjustable bed device is equipped with, for example, a head-lifting mechanism for lifting the head, a back-lifting mechanism for lifting the back, and a knee-lifting mechanism for lifting the knees.

When the mattress 1 is placed in the adjustable bed device as described above, in the Y direction, the second part P21 is provided at a position corresponding to the head-raising mechanism, the second part P22 is provided at a position corresponding to the back-raising mechanism, and the second part P23 is provided at a position corresponding to the knee-raising mechanism.

The position of the second region A2 in the side walls 13, 14 can be set appropriately depending on the part where the mattress 1 is folded. The number of second portions P2 in the side walls 13, 14 can be set appropriately depending on the part where the mattress 1 is folded. In this embodiment, three second portions P2 are provided on each of the side walls 13, 14, but the number of second portions P2 provided may be two or less, or four or more.

In this configuration of the interior body 3, the upper surfaces of the cushion material 6A, the head side protection material 8A, and the wall member 10 correspond to the upper surface 31 of the interior body 3, and the lower surfaces of the cushion material 6B, the head side protection material 8B, and the wall member 10 correspond to the lower surface 32 of the interior body 3.

Here, we will explain the process for forming the wall member 10 in the manufacturing method of the mattress 1.

Figure 7 is a schematic cross-sectional view showing the process for forming the wall member 10. Figure 8 is a schematic partial enlarged view of the workbench 100 shown in Figure 7. Some members such as the sheet member 9 are not shown in Figure 7.

When forming the wall member 10, the laminate M is placed on the workbench 100. The laminate M is made up of the cushioning material 6B, the protective material 5B, the spring unit 4, the protective material 5A, and the cushioning material 6A stacked in this order.

Furthermore, the head side protection material 8B, the head side cushion material 7, and the head side protection material 8A are stacked in this order on the head side of the spring unit 4 in the laminate M. A portion of the head side protection materials 8A and 8B overlaps with the cushion materials 6A and 6B.

The workbench 100 is provided with a number of frame bodies 110. The frame bodies 110 are connected to the ends of the workbench 100, for example, by hinges, and can be rotated from a lying position as shown by the dashed lines to an upright position as shown by the solid lines. The frame bodies 110 can be formed, for example, from a metal material, a resin material, wood, or the like.

The frame 110 is provided on the four sides of the stack M. Along the sides of the stack M corresponding to the side walls 13, 14, members P2M corresponding to the second portion P2 are arranged. The lower surface of the member P2M is in contact with the upper surface of the workbench 100. The number of members P2M to be arranged is determined appropriately according to the number of second regions A2. For example, in this embodiment, three members P2M are arranged.

When the frame body 110 is raised, the side peripheral surface of the laminate M is surrounded by the frame body 110. A gap G is formed between the frame body 110 and the laminate M. The member P2M can be held in a predetermined position by being sandwiched between the laminate M and the frame body 110. The member P2M may be placed in the gap G after the frame body 110 is raised.

After the frame body 110 is erected, the liquid agent Q that is the source of the first portion P1 is injected into the gap G through the injection hole 120 (shown in FIG. 8). The injection hole 120 is provided, for example, in each of the multiple frame bodies 110.

The liquid agent Q is a mixture of two liquids, for example, isocyanate Q1 and polyol Q2. For example, isocyanate Q1 and polyol Q2 are mixed in a predetermined ratio so that the foam that forms the first portion P1 becomes hard.

The liquid agent Q injected into the gap G foams, forming the first portion P1. The work table 100 and the laminate M may be temperature-controlled at a predetermined temperature, for example, before, during, and after the liquid agent Q is injected.

The length of the member P2M in the Z direction is smaller than the length of the laminate M in the Z direction. Therefore, as shown in FIG. 7, a flow path R through which the liquid agent Q flows can be formed above the member P2M.

As a result, the liquid Q flows through the gap G along the side circumferential surface of the laminate M, allowing the liquid Q to flow around the member P2M. The tape 20 (shown in FIG. 3) prevents the liquid Q from flowing between the spring unit 4 and the head-side cushion material 7.

A wall member 10 having a first portion P1 and a plurality of second portions P2 is formed between the laminate M and the frame 110. A first region A1 and a second region A2 are formed in the side walls 13 and 14. The second region A2 can be formed in the side walls 13 and 14 depending on the position of the member P2M.

After the wall member 10 is formed, the frame 110 is removed. This forms the inner body 3 in which the wall member 10 is integrated with the spring unit 4 and other components. The mattress 1 is then completed through a process of covering the inner body 3 with the outer body 2, etc.

As shown by the dashed line in FIG. 7, the frame body 110 may have a protrusion 130 that protrudes toward the laminate M. At least one protrusion 130 is provided for each frame body 110. The protrusion 130 is formed, for example, in a cylindrical shape.

The protrusion 130 is detachably attached to the frame 110, for example, by a magnet or the like. At a position corresponding to the protrusion 130, an air hole penetrating the inner peripheral surface 11 and the outer peripheral surface 12 can be formed in the wall member 10.

For example, multiple (e.g., two) ventilation holes are formed in each of the side walls 13 and 14. Because the space enclosed by the wall member 10 is not sealed by the ventilation holes, the spring unit 4 can smoothly elastically deform when subjected to a load. The ventilation holes make it difficult for moisture to accumulate inside the spring unit 4, thereby suppressing corrosion of the spring body 41 of the spring unit 4, etc.

In the mattress 1 configured as described above, the wall member 10 has a first region A1 and a second region A2 that is aligned with the first region A1 and is softer than the first region A1. The second region A2 includes a second portion P2 that is made of a foam that is softer than the foam that forms the first region A1.

In this embodiment, since the second portions P2 are provided on the side walls 13 and 14, the second regions A2 are formed on the side walls 13 and 14, respectively. Therefore, the inner body 3 is easy to bend at the positions where the second regions A2 are formed. As a result, it is possible to provide a mattress 1 that can be folded according to the user's posture.

In this embodiment, the side walls 13, 14 include multiple (e.g., three) second regions A2 spaced apart from one another. Therefore, the mattress 1 can be provided with easy-to-fold regions at positions corresponding to, for example, the head-raising mechanism, back-raising mechanism, and knee-raising mechanism of the adjustable bed device. From the perspective of the adjustable bed device, the mattress 1 according to this embodiment can be easily folded when the bed plate is bent.

Furthermore, in the X direction, the frame line 44 is not located between the second portions P22, P23 of the side wall 13 and the second portions P22, P23 of the side wall 14, so the folding of the inner body 3 is not hindered by the frame line 44 in the second area A2 where the second portions P22, P23 are located.

Furthermore, because the first portion P1 of the wall member 10 is formed from a relatively hard foam, the wall member 10 can reinforce the side periphery of the spring unit 4. This prevents the side periphery of the spring unit 4 from sinking, allowing the spring unit 4 to be effectively used up to its side periphery. As a result, the mattress 1 according to this embodiment can provide a mattress 1 that ensures a usable area on the mattress 1 and is easy to fold.

According to the manufacturing method of the mattress 1 according to the present embodiment configured as described above, it is possible to obtain a wall member 10 having a first region A1 and a second region A2. More specifically, it is possible to form a wall member 10 having a first region A1 and a second region A2 using the member P2M and the liquid agent Q.

The length of the member P2M in the Z direction is smaller than the length of the laminate M in the Z direction. As described with reference to FIG. 7, a flow path R through which the liquid agent Q flows can be formed above the member P2M.

This allows the liquid Q to flow through the gap G along the side circumferential surface of the laminate M. Furthermore, by sandwiching the member P2M between the laminate M and the frame 110, the position of the member P2M in the gap G can be easily determined.

According to this embodiment, it is possible to provide a mattress 1 and a manufacturing method thereof that can be folded in accordance with the user's posture. The above embodiment does not limit the scope of the present invention to the configuration disclosed in the embodiment. The present invention can be implemented by modifying the configuration disclosed in this embodiment in various ways.

For example, the mattress 1 can be constructed by combining the outer body 2 of this embodiment with an inner body 3 having a structure different from that of this embodiment. The mattress 1 can also be constructed by combining the inner body 3 of this embodiment with an outer body 2 having a structure different from that of this embodiment.

In this embodiment, the inner body 3 is constructed by laminating protective materials 5A, 5B, cushioning materials 6A, 6B, etc., on the upper and lower surfaces of the spring unit 4, but the structure of the inner body 3 is not limited to this example.

For example, the spring unit 4 may be composed of multiple independent coil springs. For example, the inner body 3 may not have the head-side cushioning material 7 and the head-side protection materials 8A, 8B. The wall member 10 may further have a connecting portion for connecting to the outer body 2, for example. The mattress 1 may also be used with the upper and lower surfaces interchangeable.

In this embodiment, the second portion P2 is provided on the side walls 13 and 14, which are the long sides, but it may also be provided on the side walls 15 and 16, which are the short sides. This allows the second area A2 to be formed on the side walls 15 and 16. As a result, the mattress 1 can be easily folded around an axis along the Y direction.

As another example, the second portion P2 may form a plurality of second regions A2 aligned in the X direction on the head side side wall 15. This makes it easier to fold the corners of the mattress 1 toward the center in the X direction on the end portion 33 side. By folding the corners of the mattress 1 toward the center in the X direction, the user is less likely to fall off the mattress 1 when the back is raised.

The second portion P2 may be provided on each of the long side walls 13, 14 and the short side walls 15, 16. The second portion P2 only needs to be provided on at least one of the side walls 13 to 15. This makes it possible to provide a mattress 1 that can be folded according to the user's posture.

In the Z direction, the second portion P2 may be located between the first portion P1 and the first portion P1. When a member P2M is disposed to form such a second portion P2, a flow path R can be formed above and below the member P2M. In the second region A2, the second portion P2 may be located above the first portion P1.

In this embodiment, a mattress 1 placed in an adjustable bed device is disclosed as an example of a mattress 1, but the configuration according to this embodiment can be applied to a bed device (sofa bed) that can be converted between a sofa and a bed device in addition to a mattress placed in an adjustable bed device.

1...mattress, 3...inner body, 4...spring unit, 10...wall member, 13, 14...side walls, A1...first region, A2...second region.

Claims (7)

A spring unit,
a wall member having a first portion made of a foam and a second portion made of a foam softer than the foam forming the first portion, the wall member surrounding the spring unit;
the wall member has a plurality of first regions formed by the first portions , and a second region formed by the first portions and the second portions overlapping in a thickness direction of the spring unit, the second region being positioned between the plurality of first regions and being softer than the first regions.
mattress. The first portion in the second region is connected to the first portions in the plurality of first regions.
2. The mattress of claim 1. The spring unit is formed in a substantially rectangular parallelepiped shape,
the wall member has a pair of side walls sandwiching the spring unit in at least one of a longitudinal direction and a width direction of the spring unit,
The pair of side walls each have the plurality of first regions and the second region ,
The second region of one of the pair of side walls faces the second region of the other of the pair of side walls .
A mattress according to claim 1 or 2 . The pair of side walls each have a plurality of the second regions arranged at intervals.
4. The mattress of claim 3 . The spring unit has a frame line provided on a peripheral edge thereof,
the peripheral portion has a portion where the frame line is not provided between the second region of the one of the pair of side walls and the second region of the other of the pair of side walls;
A mattress according to claim 3 or 4. a cushioning material disposed between the wall member and the spring unit in the longitudinal direction;
The cushioning material is located between the second regions in the width direction.
4. The mattress of claim 3. A method for manufacturing a mattress according to any one of claims 1 to 6 , comprising the steps of:
placing a stack including the spring unit on a workbench;
providing a frame surrounding a side peripheral surface of the laminate placed on the workbench;
forming the wall member between the side circumferential surface and the frame;
A manufacturing method comprising:

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