JPH11266996A - Foamed mat made of thermoplastic resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foamed mat excellent in ventilation property, compression resistance, strength feeling caused by a finger pressing effect, also light in weight, easy in folding, excellent in handleability and load distribution performance and hardly causing bedsore by forming a solid projecting part and a hollow projecting part on one surface of a thermoplastic resin formed sheet. SOLUTION: This foamed mat 1 is constituted by forming the solid projecting part 31 and the hollow projecting part 32 on one surface of the foamed sheet 2, and through-holes 41 and 42 are formed in the parts 31 and 32. Height in the parts 31 and 32 is favorable to be 3-30 mm since cushion property and ventilation property are reduced when it is lowered and strength and the finger pressing effect are reduced when it is heightened and 7-15 mm is more favorable. A diameter in the parts 31 and 32 is favorable to be 5-28 mm since molding property is reduced when it is lowered and ventilation property is reduced when it is increased and 8-20 mm is more favorable. The height and diameter in the parts 31 and 32 are favorable to be same since molding property is improved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a thermoplastic resin foam mat.

[0002]

2. Description of the Related Art Conventionally, as a foam mat for supporting a human body such as a mattress, a cushion, a leisure mat, etc., hygiene,
A lightweight and inexpensive thermoplastic resin foam mat which is excellent in durability, compression resistance, etc., and is inexpensive is often used. However, in the case of a sheet-shaped foam mat having a normal smooth surface, if the center of gravity of the body cannot be changed due to sickness, injury, etc., it becomes impossible to disperse the load and support the body. There is a problem that the blood flow at the site where the patient is located is obstructed by the compression, causing bedsores.

As a method of improving the load dispersibility of a foamed mat, for example, Japanese Patent Publication No. 6-61353 and Japanese Patent Publication No. 6-61354 disclose a method of processing a thermoplastic resin foam mat into a shape conforming to the body shape. It is shown. In this method, the contact area between the body and the foam mat increases,
Although the load is easily dispersed, there is a problem that the air permeability is extremely poor because a sufficient gap cannot be secured between the foamed mat and the body.

Japanese Patent Publication No. 8-281667 discloses a mat having a finger pressure effect by changing the shape of a continuous cushion body so that a portion corresponding to the waist is harder than the other portions and has a finger pressure effect. The mat also has a problem that a sufficient gap cannot be secured between the foamed mat and the body, and the air permeability is not sufficient.

Further, Japanese Patent Publication No. 6-34798 discloses a thermoplastic resin foam mat having convex portions on both sides, but the foam mat has insufficient compression resistance.
In addition, it is difficult to fold because it has convex parts on both sides,
There was a problem that handling was poor.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a breathable material, excellent compression resistance, excellent strength and tactile sensation due to acupressure effect, light weight, easy to fold, excellent handling, and
An object of the present invention is to provide a thermoplastic resin foam mat having good load dispersibility and hardly causing bed slippage.

[0007]

The thermoplastic resin foam mat according to the first aspect of the present invention is characterized in that a solid convex portion and a hollow convex portion are formed on one surface of a thermoplastic resin foam sheet. And

According to a second aspect of the present invention, there is provided a thermoplastic resin foam mat on one surface of a thermoplastic resin foam sheet, a convex portion having a circular bottom and a semicircular cross section, and a semicircular cross section having a semicircular bottom. A semi-elliptical convex portion is formed.

According to a third aspect of the present invention, there is provided a thermoplastic resin foam mat in which one side of the thermoplastic resin foam sheet has a substantially rectangular cross-section and a substantially quadrangular bottom surface at substantially equal intervals and has convex portions. The gap between the portions is formed in a lattice shape, and the height of the convex portion is 2 to 10 times the thickness of the thermoplastic resin foam sheet.

[0010] The thermoplastic resin foam sheet used in the invention according to claims 1 to 3 (hereinafter referred to as "foam sheet")
It is preferable to use closed-cells because they have excellent compression resistance and strength and are easy to mold.

As the thermoplastic resin constituting the foamed sheet, any conventionally used thermoplastic resin can be used, and examples thereof include an olefin resin and a urethane resin.
Among them, olefin-based resins are preferred because they have excellent fluidity and are easy to mold. As the olefin-based resin, ethylene-based resins and propylene-based resins are generally used.

The thermoplastic resin is preferably crosslinked by any conventionally known method such as an electron beam crosslinking method, a chemical crosslinking method and a silane crosslinking method. The degree of crosslinking is
Generally, 35 to 50% is preferable, and more preferably 35 to 50%.
~ 45%.

An antibacterial agent, a fungicide, a flame retardant, a pigment and the like may be added to the thermoplastic resin as needed as long as the physical properties are not impaired.

The apparent density of the foamed sheet is preferably from 0.03 to 0.10 g / cc, more preferably from 0.04 to 0.10 g / cc, because the smaller the apparent density, the lower the compression resistance and strength, and the larger the apparent density, the lower the cushioning property. 08 g / cc.

Hereinafter, the present invention will be described in more detail with reference to the drawings. FIG. 1 is a cross-sectional view showing one embodiment of the thermoplastic resin foam mat of the first aspect of the present invention. The thermoplastic resin foam mat 1 has a solid convex portion 31 and a hollow portion on one surface of a foam sheet 2. The convex portion 32 is formed, and the solid convex portion 3 is formed.
The through-holes 41 and 42 are formed in 1 and the hollow convex portion 32.

In FIG. 1, the height of the solid convex portion 31 and the hollow convex portion 32 indicated by t ₁ becomes lower when the cushioning property and the air permeability decrease, and when the height increases, the strength and the finger pressure effect decrease. 30 mm is preferred, and more preferably 7 to 15 m
m. The diameter of the solid convex portion 31 and the hollow convex portion 32 is preferably 5 to 28 mm, more preferably 8 to 8 mm, since the moldability decreases when the diameter decreases and the air permeability decreases when the diameter increases.
20 mm. Note that the height and diameter of the solid convex portion 31 and the hollow convex portion 32 are preferably the same because moldability is improved.

The total number of the solid convex portions 31 and the hollow convex portions 32 is 10 to 200/100 cm, since the compression resistance decreases as the number decreases and the air permeability and moldability decrease as the number increases.
² is preferred, and more preferably 10 to 60 / 100c
m ² , preferably 40 to 65% of the total area.

The ratio between the solid projection 31 and the hollow projection 32 is not particularly limited, and may be appropriately designed according to the application. For example, in the case of a mattress, a hollow convex part 32 is formed in a part (head, shoulder, sacral part, heel part, etc.) where a high load is applied when a person lays down, and a solid convex part is formed in other parts. It is preferable to form the part 31. By forming the hollow convex portion 32 in the high load portion, the hollow convex portion 32 is set and the load dispersibility is improved.

It is preferable that through holes 41 and 42 are formed in the solid convex portion 31 and the hollow convex portion 32 in order to improve air permeability. The size of the through-hole is not particularly limited as long as compression resistance, strength and the like are not impaired.

FIG. 2 is a plan view showing an embodiment of the thermoplastic resin foam mat according to the second aspect of the present invention, and FIG. 3 is a sectional view taken along line XX 'of FIG. The thermoplastic resin foam mat 5 has, on one surface of the foam sheet 6, a convex portion 71 having a circular bottom and a semicircular cross section (hereinafter, referred to as a “circular convex portion”), and an elliptical bottom and a half cross section. Circular or semi-elliptical protrusions (hereinafter referred to as
72) are alternately formed.

In FIG. 3, the height of the circular convex portion 71 and the elliptical convex portion 72 indicated by t ₃ is preferably 5 to 15 mm because the air permeability decreases as the height decreases and the moldability decreases as the height increases. More preferably, it is 8 to 12 mm. The heights of the circular convex portion 71 and the elliptical convex portion 72 are preferably the same because the moldability, the acupressure effect and the load resistance are improved.

The diameter of the circular convex portion 71 is preferably 15 to 30 mm, more preferably 15 to 25 mm, because the smaller the diameter, the lower the air permeability and moldability, and the larger the diameter, the lower the air permeability and the acupressure effect.

The shorter diameter of the elliptical convex portion 72 is preferably 15 to 30 mm, and more preferably 15 to 30 mm, and more preferably 15 to 30 mm because the smaller the diameter, the lower the moldability, compression resistance and acupressure effect. It is preferably 25 mm, which is the same as the diameter of the circular convex portion 71, since formability, compression resistance, and the effect of finger pressure are improved. When the major axis of the elliptical convex portion 72 is smaller, the compression resistance and the acupressure effect are reduced, and when the major axis is larger, the air permeability and the acupressure effect are reduced. Therefore, the major axis is preferably 1.1 to 3 times the minor axis, more preferably 1. 4-2.
5 times.

The arrangement of the circular convex portions 71 and the elliptical convex portions 72 is not particularly limited, and may be appropriately designed according to the use. However, as shown in FIG. Moldability,
It is preferable because the air permeability and the compression resistance are improved.

The total number of the circular convex portions 71 and the elliptical convex portions 72 is not particularly limited, and may be appropriately designed according to the intended use. And 30 to 60% of the total area, and more preferably 4 to 60% of the total area.
5 to 55%.

FIG. 4 is a sectional view showing an embodiment of the thermoplastic resin foam mat according to the third aspect of the present invention. The thermoplastic resin foam mat 8 has a substantially rectangular cross section on one surface of a foam sheet 9. There are convex portions 10 having a substantially square bottom surface formed at substantially equal intervals and in such a manner that the gaps between the convex portions 10 are in a lattice shape.

The convex portion 10 has a rectangular cross section, but the corner portion has a smooth curved surface.

In FIG. 4, the height of the projection 10 indicated by t ₅ is:
Lower becomes the ventilation, acupressure effect and cushioning property is lowered, so becomes higher when the compression resistance and strength is lowered, the thickness of the foam sheet 9 shown in FIG. 5 t ₆ to be described later 2-10
Times, preferably 3 to 8 times, generally 3 times.
It is preferably from 30 to 30 mm, more preferably from 4 to 15 mm.

If the size of the projection 10 is too small or too large, the air permeability and the acupressure effect decrease, so that the length of one side of the bottom surface is preferably 10 to 30 mm, more preferably 15 to 25 mm. is there.

The distance between the convex portions 10 is preferably 1 to 5 mm because the air permeability and the acupressure effect are reduced when the protrusions 10 are narrow, and the folding resistance is difficult and the handleability is reduced. , More preferably 2-4
mm.

The projections 10 are formed such that the gaps between the projections are in a lattice pattern. By forming in this manner, the thermoplastic resin foam mat can be easily folded, and handleability is improved.

In FIG. 1, the thickness of the foam sheet 2 indicated by t ₂ , the thickness of the foam sheet 6 indicated by t ₄ in FIG.
Among, the thickness of the foam sheet 9 shown in t ₆ is a moldability is lowered thin, folded becomes difficult and becomes thick, 1 to 7 mm are preferred because even the handling property is lowered to increase the weight, and more preferably Is 2 to 5 mm.

Further, the thickness of the thermoplastic resin foam mat as a whole is 4 to 3 since the cushioning property and the compression resistance are reduced when the mat is thin, and it is difficult to fold and the handleability is reduced when the mat is thick.
It is preferably 5 mm, more preferably 8 to 15 mm.

The method for obtaining the thermoplastic resin foam mat according to the first to third aspects of the present invention is not particularly limited, and any conventionally known method may be employed. There is a method of press-molding with a mold.

FIG. 5 is a schematic sectional view showing an example of the method for producing a thermoplastic resin foam mat according to the first aspect of the present invention. The foam sheet 11 is pressed by a mold comprising an upper mold 12 and a lower mold 13. It shows the state that it is doing. The upper mold 12 is formed with a recess 15 of an arbitrary shape having a deaeration port 14, and the lower mold 13 has a projection 17 on a smooth surface 16 as necessary.
Are formed. In addition, the protrusion 17 of the foamed sheet 11 is used.
Are formed with hollow projections, and the other portions are formed with solid projections.

In the case of the thermoplastic resin foam mat according to the second and third aspects of the present invention, the lower mold 13 is used as the smooth surface 1
It is obtained in the same manner as described above, using the one having only 6.

During press molding, the foamed sheet 11 is heated. If the heating temperature is too low or too high, the moldability is reduced, and the surface of the foamed mat after molding on which the convex portions are not formed ( (Hereinafter referred to as “back side”)
20 to more than the melting point of the thermoplastic resin constituting the foam sheet
Preferably, the temperature is raised by 50 ° C. Further, the surface temperature of the foamed sheet is 150 to 180 ° C, and the internal temperature is 110 to 140 ° C.
It is preferred that

The pressing pressure at the time of press molding is 4,000 kgf / cm ² because it is difficult to form a convex portion when the pressing pressure is small.
It is preferable that this is the case.

When the compression speed during press molding is reduced, the moldability is reduced. When the compression speed is increased, the back surface of the foamed mat after the molding is roughened, and the compression resistance is reduced due to generation of abnormal bubbles. It is preferably from 0.5 to 0.2 m / sec.

If the compression ratio is too small, no projections are formed or the back surface of the foam mat becomes rough, and if it is too large, foam breaks or the foam sheet is broken. Is preferably 5 to 40% of the thickness.

By performing the press molding under the above conditions, the bubbles in the convex portion are oriented in the thickness direction, and the compression resistance in the thickness direction is improved. The ratio of the orientation in the thickness direction is such that the cell diameter in the thickness direction is 1.1 times the cell diameter in the length direction or the width direction.
It is preferably up to 2.5 times.

The thermoplastic resin foam mat includes:
A soft foam sheet having a smaller compressive strength than the foam sheet may be laminated on the back surface.

FIGS. 6 and 7 are cross-sectional views showing a state in which a soft foam sheet is laminated on the thermoplastic resin foam mat shown in FIGS. 1 and 3.

In FIG. 6, reference numeral 1 denotes the thermoplastic resin foam mat shown in FIG. 1, and a soft foam sheet 18 having a smaller compressive strength than the foam sheet 2 is laminated on the back surface.

In FIG. 7, reference numeral 5 denotes the thermoplastic resin foam mat shown in FIG. 3, and a soft foam sheet 19 having a smaller compressive strength than the foam sheet 6 is laminated on the back surface.

The flexible foam sheets 18 and 19 may be closed-cell or open-cell.
As the resin constituting the flexible foam sheets 18 and 19,
For example, olefin-based resins, urethane-based resins, and the like can be given.

The apparent densities of the flexible foam sheets 18 and 19 are not particularly limited. However, when the density is small, the compression resistance is reduced, and when the density is large, deformation due to compression cannot be followed.
Since the weight increases and the handleability decreases, 0.03 to 0.0.
08 g / cc is preferred, and more preferably 0.04 to
0.06 g / cc.

When the thickness of the flexible foam sheets 18 and 19 is too small, it cannot follow the deformation due to compression, and when the thickness is too large, it becomes difficult to fold and the handleability deteriorates. It is preferably about 2 to 4 times, and generally 15 to 90 mm,
More preferably, it is 30 to 80 mm.

The foam sheets 2 and 6 and the soft foam sheet 18
And the method of laminating 19 may be any conventionally known method, for example, a method using an adhesive, a method using heat fusion, and the like.

[0050]

The foamed thermoplastic resin mat according to any one of the first to third aspects of the present invention has the above-described structure, so that it has good load dispersibility, hardly causes bed slippage, and has excellent compression resistance and strength. It is hard to set and has a sufficient gap between the foam mat and the body, so that it is excellent in air permeability. In addition, there is an acupressure effect by the convex portion, and the touch feeling is excellent. Furthermore, it is easy to fold, lightweight and easy to handle.

In the thermoplastic resin foam mat according to the first aspect of the present invention, since a hollow convex portion is formed in a portion where a high load is applied, load dispersibility is improved, and floor slippage is less likely to occur. The thermoplastic resin foam mat of the invention according to claim 2 is
The elliptical convex portion improves the compression resistance and the acupressure effect, and since the circular convex portion is mixed, a sufficient space can be secured between the foam mat and the body, and the air permeability is excellent. The thermoplastic resin foam mat according to the third aspect of the present invention is easy to fold in both the length direction and the width direction because the gaps between the convex portions are in a lattice shape, and is excellent in handleability.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a thermoplastic resin foam mat according to the first aspect of the present invention.

FIG. 2 is a plan view showing one embodiment of a thermoplastic resin foam mat according to the second aspect of the present invention.

FIG. 3 is a sectional view taken along line X-X 'of FIG.

FIG. 4 is a cross-sectional view showing one embodiment of the thermoplastic resin foam mat according to the third aspect of the present invention.

FIG. 5 is a schematic sectional view showing an example of the method for producing a thermoplastic resin foam mat according to the first aspect of the present invention.

FIG. 6 is a cross-sectional view showing a state in which a soft foam sheet is laminated on the thermoplastic resin foam mat of FIG.

FIG. 7 is a cross-sectional view showing a state in which a soft foam sheet is laminated on the thermoplastic resin foam mat of FIG.

[Description of Signs] 1, 5, 8 Thermoplastic resin foam mat 2, 6, 9, 11 Foam sheet 31 Solid convex portion 32 Hollow convex portion 41, 42 Through hole 71 Circular convex portion 72 Elliptical convex portion 10 Convex Part 18, 19 Flexible foam sheet

Claims (3)

[Claims] 1. A thermoplastic resin foam mat, wherein a solid convex portion and a hollow convex portion are formed on one surface of a thermoplastic resin foam sheet. 2. A projecting part having a circular bottom and a semicircular cross section and a convex part having a semicircular or semicircular cross section on one side of a foamed thermoplastic resin sheet. A thermoplastic resin foam mat characterized by the following. 3. On one surface of the thermoplastic resin foam sheet, convex portions having a substantially rectangular cross section and a substantially square bottom surface are formed at substantially equal intervals, and the gaps between the convex portions are formed in a lattice shape. Wherein the height of the projections is 2 to 10 times the thickness of the thermoplastic resin foam sheet.