JPH034269Y2 - - Google Patents

Description

[Detailed description of the invention] The present invention is a health mat that has a large number of protrusions (uneven shapes) and has an acupressure effect on the human body. Regarding Matsuto.

In recent years, healthy mats have been made using harder materials (such as polyethylene) as core bodies instead of simple cushion bodies made of only soft cushioning materials (for example, urethane foam), thereby improving the overall strength of the mat. In addition, products are becoming available that have protrusions formed on both the cushion body and the core body to enhance the acupressure effect.

Conventional health mats containing this type of core are
The core body and the two cushion bodies laminated on both sides of the core body were separately molded, and then bonded together to form a single body.

Therefore, because the core body to be included has a specific shape formed in advance, there are difficulties in the bonding process, and good adhesion cannot always be obtained.
There was a problem in that the desired acupressure effect could not be expected.

On the other hand, mats manufactured without using the process of bonding the cushion body and the core body have also been proposed. The urethane foam and the plastic sheet are both interposed and then heated to form an uneven shape. However, even in this case, although the acupressure effect is excellent due to the hardness of the plastic sheet due to its uneven shape, the plastic sheet obstructs the breathability of the entire mat, making it difficult to absorb sweat from the body due to long-term use. had the disadvantage of not being able to fully respond.

The inventors of the present invention have conducted studies to solve the above-mentioned problems, and have created a healthy mat by interposing a core inside the urethane foam sheet and giving the entire mat an uneven shape by heat molding. When a sheet (web) made of short thermoplastic synthetic fibers treated with a latex binder was used as the core, the web was cured while retaining its uneven shape, such as a wave shape, during the heat molding stage. They newly discovered that the mat has a hardness sufficient to produce an acupressure effect, and the fiber web ensures breathability throughout the mat, making it an extremely healthy mat, and completed the present invention.

That is, the present invention is a urethane foam sheet in which a urethane foam sheet is heat-molded and has an uneven shape, and a sheet (web) in which short fibers of thermoplastic synthetic fibers are treated with a latex binder inside the urethane foam. The present invention relates to a high-hardness healthy mat that is hardened by heat molding and includes molded uneven parts. The sheet interposed inside the urethane foam in the mat of the present invention is made of relatively thick short thermoplastic synthetic fibers molded into a plate shape using a latex binder, and is different from a thermoplastic sheet. ,
It is web-like with breathability. This sheet exhibits good adhesion to the polyurethane foam during heat molding, and also has appropriate hardness after being cured by molding and having an uneven shape formed thereon.

In this case, the short synthetic fibers are preferably made of polypropylene, polyester, etc., and are relatively thick, for example around 10 deniers.

As a short fiber web of such synthetic fibers,
For example, there are sand mats used in civil engineering work to prevent soil outflow.
It can be used in the form of a sheet of about 10 m/m. This commercially available sand mat has a softening point of 140~
The temperature is 160℃, the short fibers are formed into a web shape with a latex binder, and have good breathability.The short fibers are treated with a latex binder, so they have good adhesion to polyurethane foam. It turned out to be.

The present invention will be explained in more detail below with reference to the drawings.

FIG. 1 shows a longitudinal section of a high-hardness healthy pine according to the present invention.

The health mat 1 consists of a web 5 made of polyurethane foam and short fibers of synthetic resin fibers interposed inside the polyurethane foam treated with a latex binder, and the web 5 is held between an upper polyurethane foam 2 and a lower polyurethane foam 3. It exists. Then, the mat 1 is given an uneven shape to the entire mat by heat molding, and the convex portions 6 and concave portions 7 of the polyurethane layer,
It also has the shape of a convex portion 8 and a concave portion 9 of the web.

In this case, since the web 5 interposed inside the polyurethane foam layer is a thermoplastic fiber composed of a large number of short fibers in a sheet shape, it is hardened during heat molding, and the convex portions 8 and concave portions 9 exhibit an acupressure effect. The hardness is as high as possible.
Therefore, at the stage of using the mat 1, the convex portions of the polyurethane foam layer 2 exhibit cushioning properties, and the body is supported at multiple points on the convex portions 8 of the web existing in the underlying layer, resulting in an acupressure effect. is demonstrated.

Note that the mat 1 can be used as it is by surrounding it with cloth, etc., but in order to ensure the aesthetic appearance of the mat surface, a stretchable and heat-resistant fabric 15 (for example, ester/ It is also possible to obtain matte with a textured surface by laminating circular knitted rayon piles and heat forming them. Such a modification is shown in FIG.

Further, the web 5 interposed inside the polyurethane of the mat 1 does not need to be present on the entire surface of the mat, and for example, the peripheral edge 10 of the mat may be made only of polyurethane foam. Therefore, flexibility is ensured at the peripheral edge 10 where the web 5 is not present, and it is also possible to finish the edge by sewing.

Next, the method for manufacturing the high hardness healthy pine according to the present invention will be explained using an example.

First, as shown in FIG. 3, a laminate 14 in which a web is sandwiched between upper and lower polyurethane foams is placed in a mold 11 consisting of a lower mold 12 and an upper mold 13 having a specific uneven shape, and heated and heated. Perform pressure molding.

The laminate 14 placed in the mold 11 in this case is shown in FIG.

The laminate 14 has a web 5 formed by the upper polyurethane foam 2 and the lower polyurethane foam 3.
are sandwiched, and the web 5 is not present on the peripheral edge 10 thereof. Moreover, this laminate 14 can also be formed by further laminating a heat-resistant and stretchable fabric on top of the polyurethane foam 2.

The web 5 is formed into a plate shape by spreading synthetic short fibers substantially uniformly on a base plane to a constant thickness and spraying a latex binder.

Latex binders include those commonly used, such as nitrile rubber, SBR,
A rubber binder such as natural rubber or polyurethane, or a synthetic resin binder such as vinyl acetate resin, acrylic resin, ethylene-vinyl acetate copolymer, or polyvinyl alcohol is used. The type of latex binder is appropriately selected and used depending on the required hardness of the mat, and when used, the viscosity is adjusted to allow spray application.

The laminate 14 is molded under heat and pressure in the mold 11, and the molding conditions in this case include, for example, temperature
The temperature is 180 to 250°C, the pressure is 30 to 80 kg/cm ² , and the time is about 3 to 5 minutes.

After being molded in this manner, the laminate is taken out from the mold to produce a high hardness healthy mat 1 in which the entire mat is provided with an uneven shape.

The health mat of the present invention is a web made of short thermoplastic synthetic fibers treated with a latex binder inside a polyurethane foam, which is hardened by heat molding and has a molded uneven part interposed therein. The uneven shape of the web provides an excellent acupressure effect. In addition, since the presence of the web ensures hardness, the amount of urethane used can be reduced, and since the web itself is treated with a latex binder, adhesion to the polyurethane foam layer is ensured. There is no need to use any adhesive. In particular, when holding the conventional core body between polyurethane foams, it was necessary to apply adhesive to the surfaces that were in contact with each other, which caused complexity in manufacturing, but with the mat of the present invention, This method has the advantage that such steps are not required at all, and the steps can be simplified.

Furthermore, since the web interposed inside the polyurethane foam is fibrous, it can have air permeability even after being thermally cured. This breathability is not found in conventional pine mats that use thermoplastic sheets as core bodies, and it is therefore easy to absorb sweat from the body after long-term use. It can be said that it is particularly excellent.

In addition, the health mat of the present invention can be used not only as a bedding pad, but also as similar health equipment, such as a foot seat, a back pad, a waist pad, etc.
It is also possible to apply it to pillows, shoe insoles, etc.

[Brief explanation of the drawing]

Figure 1 is a diagram showing an example of the high hardness healthy pine of the present invention, Figure 2 is a diagram showing another modification, and Figure 3 is a diagram showing another modification.
4 are diagrams showing the manufacturing method thereof. 1... mat, 2, 3... polyurethane foam, 5... web, 11... mold, 14... laminate.

Claims (1)

[Scope of Claim for Utility Model Registration] A urethane foam mat in which a urethane foam sheet is heat-molded and has an uneven shape, in which short fibers of thermoplastic synthetic fibers are treated with a latex binder inside the urethane foam mat. A high-hardness healthy pine comprising a sheet (web) that is hardened by heat molding and includes a molded uneven part.