JPH0141335Y2 - - Google Patents

Description

[Detailed description of the invention] [Industrial application field] This invention is used in futons, pillows, and other cushion products, and relates to a composite cushion material that is used inside a cloth cover. It is.

[Prior Art] Conventionally, cushion products such as futons have been manufactured using methods such as those disclosed in Japanese Utility Model Publication No. 2172-2172 and Japanese Utility Model Publication No. 50-1989.
As described in Publication No. 17706, a single cushion material is used in which a number of core bodies made of plastic sheets wrapped with many air chamber protrusions on the surface are arranged side by side and tied together with string. .

Also, Japanese Patent Application Laid-open No. 100855/1983
As described in Japanese Patent No. 5116, it is also known that a large number of semi-cylindrical pieces of flexible foamed plastic are arranged side by side and adhered to the surface of a foamed plastic plate.

Furthermore, as described in Japanese Utility Model Publication No. 55-29526, a composite cushion is made of a sheet-like multicellular polyethylene molded product in which a large number of semicylindrical shapes are connected, and a sheet-like elastic material that is softer than the molded product. The material is also known.

Furthermore, as described in Japanese Utility Model Publication No. 55-40052, it is a corrugated sheet in which a plurality of semi-cylindrical strip-shaped protrusions are arranged in a row, and a transverse groove and a bridge section are provided between each protrusion. A composite cushion material is also known in which a flexible foamed polyethylene sheet molded body is laminated by adhesive on a soft plate-shaped core material having cushioning properties.

[Problems that the invention aims to solve] As published in Utility Model Publication No. 50-2172, etc., a large number of core bodies each wrapped with a plastic sheet having a large number of air chamber protrusions on the surface are manufactured by arranging them side by side. Cushion materials such as core materials for futons are often used because they have acupressure effects due to the action of a large number of air chamber protrusions. It took a lot of time to wind it, and it was difficult to wind it in a uniform and appropriate manner.

In addition, as described in Japanese Patent Application Laid-Open No. 51-100855, a large number of semi-cylindrical single bodies are arranged side by side and adhesively fixed on the surface of a flexible foamed plastic plate. It is difficult to line them up properly and glue them together. In addition, when a force is applied to a portion of the core of a futon, etc., only the semi-cylindrical single part to which the force is applied will fall significantly, and the human body tends to partially sink into the futon. There is.

Furthermore, as described in Japanese Utility Model Publication No. 55-29526, a sheet-like molded product with a large number of consecutive semi-cylindrical shapes is provided on a flexible sheet-like elastic material. Since the area is wide and has a series of long spaces, there is no acupressure effect in that area. In addition, when a person sleeps on this, the gap between the valleys is large and penetrates straight on both sides, so air escapes and it becomes cold. Furthermore, due to the space between the valleys, the cushion material itself has a weak stiffness and is easily broken.

Furthermore, as described in Japanese Utility Model Publication No. 55-40052, even in the case of a corrugated sheet in which multiple rows of semi-cylindrical strip-shaped protrusions are arranged,
Since there is a series of long spaces between the strip-shaped protrusions, there is a drawback similar to that of the above-mentioned Japanese Utility Model Publication No. 55-29526.

That is, the conventional cushioning materials had problems such as being troublesome and difficult to manufacture, lacking sufficient acupressure effect and heat retention effect, and that the cushion material itself was easily broken.

[Means for Solving the Problems] In order to solve the above-mentioned conventional problems, the present invention provides a large number of protrusions on a substantially planar surface and curves the surfaces vertically and horizontally. A narrow groove is provided, a protrusion with a diameter larger than the width of the groove in one direction is provided at the curved part of the groove, a bottom plate is provided on the entire bottom surface, the entire outer periphery is a vertical surface from the bottom to the top, and the inside A flexible hollow outer core with a large number of sealed air chambers is used, and the entire plane of the bottom plate of the hollow outer core is adhered to the middle core, which is more flexible than the hollow outer core. Then, the hollow outer core and the core were stacked to form a composite cushion material. Here, the hollow outer core whose surface is substantially planar means that the surface is partially provided with thin grooves, and the surface is nailed in an appropriate number of appropriate sizes. It consists of a series of semi-independent parts each having an independent sealed air chamber inside, and the surface part of each of these semi-independent parts is approximately flat throughout the composite cushion material. .

[Function] The composite cushion material of the present invention is put into a cloth bag and made into a futon or the like. When a person sleeps on the futon, etc., the flexible hollow outer core has many protrusions on its almost flat surface and many sealed air chambers inside. Since most of the human body is in contact with the surface of the futon or the like, a sufficient acupressure effect is applied to the entire human body to improve blood circulation within the human body.

In this case, since a flexible hollow outer core is provided which is formed in one piece, even if a person's weight acts on a portion of the core, the hollow core will not slump significantly. Good cushioning action is achieved without the wall surfaces of the sections spreading laterally. In addition, the surface that the human body comes into contact with through the cloth is almost flat, which not only produces acupressure effects on the entire surface, but also prevents air from escaping between the human body and the hollow outer core, providing warmth. can be maintained. In addition, the hollow outer core with a flexible surface also has a cushioning effect due to the action of the air in the sealed air chamber, which is completely sealed and has elasticity in each chamber. Due to the spring-like effect and the effect of alleviating initial compressive stress, the human body is less likely to fall.
In addition, due to the synergistic effect with the flexible core, it can cope with relatively small movements and vibrations.
It works comfortably even when a person sleeps on it and turns over.

[Example] Next, the present invention will be explained in more detail with reference to an example shown in the drawings.

In one embodiment shown in FIGS. 1 to 5, 1 is a flexible hollow outer core, 2 is a middle core that is more flexible than the hollow outer core 1, and the hollow outer core 1 has its entire bottom surface. The planes are placed on top of each other in close contact with the outside of the core body 2 and attached with adhesive.

The hollow outer core body 1 has a substantially planar surface as a whole, and has a large number of low small protrusions 3 appropriately arranged on the surface, and the entire outer periphery is a vertical plane from the bottom to the top. Moreover, it has a large number of sealed air chambers 4 inside.

The hollow outer core body 1 is integrally formed with an outer surface portion 5 made of the same material and a flat bottom plate portion 6 provided on the entire bottom surface. External part 5 and bottom plate part 6
When integrating the outer surface part 5, the outer surface part 5 is supplied by embossing for continuous molding, and at this time, it is pressed together with a male mold to obtain a sharp corner of the recessed part, while the bottom plate Part 6 is supplied with a laminate of molten polyethylene, and the two are pressed together to continuously integrate them. Note that the outer surface portion 5 and the bottom plate portion 6 may be integrally formed from the beginning, for example, by vacuum forming. It is also possible for the outer surface part 5 and the bottom plate part 6 to be manufactured separately and firmly integrated with each other by means of an adhesive.

The outer surface portion 5 having a large number of protrusions 3 is, for example,
As shown in Figure 2, so that the cross shape and the H shape appear to fit into each other, thin grooves 7 are partially provided, and the surface is nailed with an appropriate number of appropriate sizes. The flat surface of each of these semi-independent parts is approximately the same as that of the entire hollow outer core 1, avoiding a completely flat surface and increasing the number of semi-independent parts each having a sealed air chamber inside. By making it flat, the acupressure effect can be maintained sufficiently. A protrusion 3a having a diameter larger than the width of the groove 7 is provided at the bent corner of the groove 7 for reinforcement and to prevent breakage at the groove 7 portion. The surface position of the protrusion 3a was made to be on the same plane as the surface position of the protrusion 3. Note that the back side of the portion where these grooves 7 are located is a rib portion 8, and since it is integrated with the bottom plate portion 6, this portion also acts as a reinforcing member.

The outer surface portion 5 is made of, for example, a 20-40 times foamed cross-linked polyethylene sheet with a thickness of 20-40 mm, and the protrusions 3, 3a have a diameter of 10-30 mm and a height of 5 mm, for example.
Made to ~10mm. The spacing between adjacent grooves 7 and the spacing between rib portions 8 may be, for example, 50 to 50 mm in narrow spaces.
100mm, 100 to 2000 in wide areas, to avoid weakening by making it too wide or long. The outer surface portion 5 and the bottom plate portion 6 of the hollow outer core 1 can be formed into an integral shape from the beginning in a continuous work flow as described above.
This can also be done by making the outer surface part 5 and the bottom plate part 6 separately and then gluing them together later. In order to make the outer surface portion 5, for example, foamed crosslinked polyethylene having a skin layer on the surface is molded into an uneven pattern using female vacuum suction and male pressure molding. In this case, the surface skin layer may have already been formed during the pressure molding of the foam sheet, but especially when it is sliced and processed for secondary processing, the surface layer is melted by heat radiation or heated rolls to form a coating. or skinned by lamination.

When the bottom plate portion 6 is made separately from the outer surface portion 5 and attached to the outer surface portion 5, it is made of, for example, a non-foamed or 3 to 5 times low foamed polyethylene sheet and has a thickness of 1 to 10 mm, preferably, It was set to 3 to 6 mm. This bottom plate part 6 is also provided with cushioning properties, and the top part 5 and bottom plate part 6 form a sealed air chamber 4 to prevent air from escaping, thereby utilizing the cushioning properties of the air itself. . Note that the foaming ratio of the bottom plate portion 6 and the outer surface portion 5 can also be made the same. In addition to the foamed polyethylene sheet, the bottom plate portion 6 can also be made of a rigid foamed sheet made of resin such as polyester.
Preferably, it is made of the same material as the outer surface portion 5.

In other words, the outer surface portion 5 and the bottom plate portion 6 are integrated as if air bubbles are sealed in the hollow portion, and appropriate cushioning properties, spring action, and similar initial compressive reaction force relaxation characteristics are intertwined in a different way. In order to exhibit the overall characteristics of the hollow outer core 1, it is appropriate that the bottom plate portion 6 be of the same quality as the outer surface portion 5.

The bottom plate part 6 is made of, for example, polyolefin with a molecular weight of 12,000 or more and a density of 0.91 to 0.97 g/cm ³ as a raw material, and the cells are connected to each other, but the number of cells is uniformly 4,000 or more per 1 cm ³ as independent cells. Most preferred are foam sheets with a distributed density of 0.2 to 0.9 g/cm ³ .

Further, as will be described later, a three-layer sheet 14 containing air bubbles made of polyethylene film can also be mentioned as a preferable material.

The sealed air chamber 4 has a size of, for example, a bottom of 10 to 200 mm, a height of 5 to 40 mm, and a volume of 0.5 to 200 mm.
The number per cm ³ and 1 m ² was set to 100 to 300. Although it is not necessary that the sealed air chambers 4 are arranged completely evenly, it is preferable that they are not extremely concentrated in one place.

Since the core 2 is more flexible than the hollow outer core 1, the bottom plate portion 6 naturally has a higher modulus of elasticity than the core 2.

The core body 2 is made of a flexible material such as highly foamed soft urethane foam, and the hollow outer core body 1 is arranged on both sides of the core body 2, and the hollow outer core body 1 is placed on both sides of the core body 2, and the composite cushion material is made into a futon by interlacing them in a sandwich pattern. It was used as a core material. Of course, this composite cushion material can be covered with cloth or the like to make a bedding mat or the like.

The uneven pattern on the surface of the hollow outer core body 1 is not limited to the shape shown in FIG. 2, but can be made into various shapes. However, the grooves 7 formed by the concave portions of the surface unevenness pattern are straight from one end surface to the other end surface of the hollow outer core 1, regardless of whether the grooves are in the vertical, horizontal, horizontal, or diagonal directions. I don't like it being penetrated. Bending the groove 7, partially narrowing the groove width to, for example, 1 mm or less, or
It is particularly preferable to adopt a structure that obstructs the straight flow of air by completely blocking the flow of air.

In the groove 7, for example, the width of the lower part is 1 to 1.
8mm, depth 5-25mm, length 50-200mm,
In order to narrow the middle of the groove 7 and substantially stop the flow of air, the width of that part should be 1 mm or less.

Further, the patterns on the front and back sides of the composite cushion material itself, the shape and width of the grooves 7, etc. can be made different as appropriate. Of course, if you make the groove 7 on one side straight or make the width a little wider to improve ventilation, that side can be used for summer use, and the other side can be used for summer use. If the groove 7 on the surface is shaped like a hook or made narrow in width, the surface can be used for winter use. In addition, by changing the size and number of protrusions 3 on the front and back sides, one side can be used for people who are used to using this composite cushion material, and the other side can be used for people who are just beginning to use it. It can also be divided.

3 to 5 show other examples of the surface pattern of the other hollow outer core body 1. In this embodiment, a protrusion 3 having a diameter larger than the width of the groove 7 in one direction is provided at the bent portion of the groove 7.

Further, as shown in FIG. 6, a polyethylene sheet 10 having a large number of air chamber protrusions 9 on its surface may be used as the bottom plate portion 6 of the hollow outer core 1 by turning it over. This polyethylene sheet 10 is made by pasting one flat sheet 12 on the back side of a sheet 11 having air chamber protrusions 9.
As shown in the figure, it is also possible to use a three-layer sheet 14 in which one flat sheet 13 is further laminated on the air chamber protrusion 9 side. Further, the three-layer sheet 14 may be sandwiched between the hollow outer core 1 made of foamed polyethylene and the inner core 2 made of urethane foam, or the inner core made of urethane foam may be used. Instead of the core body 2, a sheet obtained by laminating several sheets 14 of the three layers described above can also be used as the core body 2.

Note that when the polyethylene sheet 10 or the three-layer sheet 14 is used for the core body 2, between the core body 2 and the hollow outer core body 1, or for the bottom plate portion 6 of the hollow outer core body 1, the hollow A small through hole is made in the rib portion 8 of the hollow outer core 1 from a part of the groove 7 of the outer core 1 to the position of the polyethylene sheet 10 or the three-layer sheet 14 to improve air permeability. If your body tries to swell, you can also make arrangements to prevent it. In addition, a through hole 1 is provided in the hollow outer core body 1.
If 5 is provided, it is provided at a position as shown as 15 in FIG. 2, for example. Of course, when using the polyethylene sheet 10 as shown in FIG. 6 as the bottom plate part 6 integrated with the outer surface part 5, the outer part of the flat sheet 12 is integrated with the rib 8 part of the outer surface part 5, and the polyethylene sheet 10 shown in FIG. When using a three-layer sheet 14 as a part of the core 2, the through holes 15
is the bottom plate part 6 of the two sheets 11 and 13.
Penetrate the sheet on the side that is in contact with. In any case, the lower end of the through hole 15 is made to communicate to the outside through 10 parts of the polyethylene sheet or 14 parts of the three-layer sheet.

[Effects of the invention] Since the invention has the structure as described in the claims of the utility model registration, it is relatively easy to manufacture a composite cushion. In addition, since we used a hollow outer core with a nearly flat surface and a large number of sealed air chambers inside, when this was used as a core for a futon, the areas on which a lot of weight would be applied would be partially You won't get too involved, and
A cushion of the material itself that does not partially sag or spread laterally, and a cushion of the air inside the sealed air chamber that completely seals the air and gives elasticity to each one. A suitable cushion can be obtained by the action. Of course, due to the synergistic effect with the flexible core, a wide range of good cushioning effects can be obtained. Since the hollow outer core under a load comes into soft contact with the flexible core over the entire surface, the buffering performance of the interposed core can be maximized in the sandwiched state.

Further, since a hollow outer core is used, there is no leg opening or air leakage in the rib portion of the hollow outer core, there is no buckling of the upper surface portion and rib portion of the hollow outer core, and there is no bending of the waist.

Furthermore, since we used a hollow outer core with a surface that is almost flat, there is a large amount of contact with the human body, and the effect of acupressure is correspondingly large. You can maintain a moderate amount of warmth without getting too cold due to too much air movement.

Furthermore, since a hollow outer core is used, less material is required in relation to the volume, and the weight can also be reduced.

Of course, since a large number of protrusions are provided on the surface of the hollow outer core, a good acupressure effect can be obtained.

In addition, in the present invention, a bottom plate part is provided on the entire bottom of the hollow outer core body, a large number of sealed air chambers are provided inside the hollow outer core body, and the entire plane of the bottom plate part of the hollow outer core body is Since the adhesive was adhered in close contact with the core, which is more flexible than the core, the bottom of the hollow outer core does not partially peel off from the core, and the bottom of the outer periphery of the hollow outer core does not separate from the core. It will not peel off, and all the sealed air chambers inside the hollow outer core will always maintain their normal shape, so there will be no air leakage, and no noise will be made when you roll over, causing discomfort. ,
It is comfortable to use because it does not make you sleepy and can always maintain sufficient heat retention and air cushioning properties.

In addition, in the present invention, the entire outer periphery of the hollow outer core is a vertical plane from the bottom to the top, and as mentioned above, the vicinity of the outer periphery of the hollow outer core does not peel off from the core. The shape of the hollow outer core body near the outer periphery does not shift, become lower, or become partially damaged, and has sufficient durability.

Furthermore, in the present invention, narrow grooves curved vertically and horizontally in a hook-like manner are provided on the almost planar surface of the hollow outer core, and the curved portion of the groove is wider than the width of the groove in one direction. The large-diameter protrusions provide adequate breathability and strength, as well as adequate cushioning properties, and the large number of protrusions provides an appropriate acupressure effect. It is comfortable to sleep on, without causing pain in your shoulders or other parts of your body. In addition, durability is ensured also by these things.

[Brief explanation of the drawing]

Figures 1 to 5 show one embodiment of the present invention.
1 is a sectional view taken along the - line in FIG. 2, FIG. 2 is a plan view, FIG. 3 is a bottom view, FIGS. FIGS. 6 and 7 are perspective views and cross-sectional views showing different examples of materials used in other embodiments of the present invention. 1...Hollow outer core body, 2...Medium core body, 3, 3a...
...Protrusion, 4... Sealed air chamber, 5... External surface part, 6
...Bottom plate part, 7...Groove, 8...Rib part, 9...
...Air chamber protrusion, 10...Polyethylene sheet, 1
4...Three-layer sheet, 15...Through hole.

Claims (1)

[Claims for Utility Model Registration] A large number of protrusions are provided on a substantially planar surface, narrow grooves curved vertically and horizontally are provided on this surface, and the curved portion of the groove has a width larger than the width of the groove in one direction. A protrusion with a large diameter is provided, and a bottom plate is provided on the entire bottom surface.
A flexible hollow outer core with a vertical surface from the bottom to the top and a large number of sealed air chambers inside is used, and the entire plane of the bottom plate of the hollow outer core is A composite cushion material formed by overlapping a hollow outer core and a core by adhering them in close contact with a flexible core.