WO2012105466A1

WO2012105466A1 - Mattress

Info

Publication number: WO2012105466A1
Application number: PCT/JP2012/051912
Authority: WO
Inventors: 重伸金子
Original assignee: システムサポート株式会社
Priority date: 2011-02-04
Filing date: 2012-01-30
Publication date: 2012-08-09
Also published as: JP2012161394A; TW201236667A

Abstract

This mattress is provided with: a first high-rebound elastic urethane foam layer (1) having a profile machined surface (11); a first low-rebound elastic urethane foam layer (2) layered on the profile machined surface (11); and a resin film layer (3) layered on the surface of at least the first low-rebound elastic urethane foam layer (2). The thickness of the first low-rebound elastic urethane foam layer (2) is 5-10 mm, and is favorably 7-9 mm. The moisture permeability (40°) of the resin film layer (3) is 1000-1500 g/m²·24h.

Description

mattress

The present invention relates to a mattress having excellent body pressure dispersibility and cushioning properties.

Conventionally, resin foams, particularly low-resilience polyurethane foams, which have excellent body pressure dispersibility and improve sleeping comfort, are often used for mattresses and other beddings. In recent years, an aging society has progressed, and the number of care recipients is increasing in hospitals, well-being facilities, and homes. Many care recipients are forced to live on the bed. As such a bed for a care recipient, a mattress in which the surface of a core material made of hard cotton or resin foam is covered with a fiber cloth is frequently used.

For example, Patent Document 1 discloses a mattress used for a bed of a care recipient in a medical institution or welfare facility. This mattress is formed by covering the surface of a core material with a urethane film that has good elongation under low load. According to this mattress, the movement of the surface portion of the mattress is made to follow the cushioning property of the core material, and the cushion effect of the mattress is sufficiently exhibited. Patent Document 2 also discloses a mat for bedding for inpatients, residents of elderly welfare facilities, and the like. This bedding mat is formed by laminating urethane foam having a predetermined density and hardness. According to this mat for bedding, it has the advantage that it is easy to handle and is easy to get up from a sleeping state.

The mattress described in Patent Document 1 and the mat for bedding described in Patent Document 2 have many characteristics required for a mattress used for a bed of a care recipient in particular in a medical institution and a health facility. ing. However, there is a need for a mattress with even better properties.

JP 2003-230605 A JP 2002-34730 A

The object of the present invention is to have excellent body pressure dispersibility and cushioning properties, and is particularly useful in medical institutions and health facilities, etc., and is light in weight so that the burden on the assistant is reduced and even if dirt is attached. It is an object of the present invention to provide a mattress that can be wiped off and the sheets are difficult to slip, reducing the labor of a caregiver, having good sleeping comfort, suppressing stuffiness, and preventing floor rubbing and the like.

In order to solve the above problems, according to a first aspect of the present invention, a first high resilience urethane foam layer having a profile processing surface, a first low resilience urethane foam layer laminated on the profile processing surface, There is provided a mattress including at least a resin film layer laminated on the surface of the first low-resilience urethane foam layer. In the mattress, the thickness of the first low resilience urethane foam layer is 5 to 10 mm, and the moisture permeability (40 ° C.) of the resin film layer is 1000 to 1500 g / m ² · 24 h.

構成 According to this configuration, body pressure dispersibility and cushioning properties are excellent, and an unpleasant push-up feeling is alleviated. Therefore, the mattress of the present invention is particularly useful in medical institutions, health facilities, and the like. Moreover, since the mattress can be lightened, the burden on the caregiver is reduced. Further, on the surface of the mattress, a resin film layer having a high strength, excellent durability, moisture permeability, air hardly leaking, and capable of maintaining air pressure is laminated. For this reason, even if dirt adheres to the mattress, the dirt can be easily wiped off. Further, if a disinfectant is used, it can be sterilized. Furthermore, if the profile processed surface is used facing upward, the acupressure effect can be achieved by the convex portion.

In the above mattress, it is preferable that the rebound resilience of the first high rebound resilience urethane foam layer is 30 to 50%, and the rebound resilience of the first low rebound resilience urethane foam layer is 5 to 15%.

According to this configuration, the body pressure dispersibility is further improved, and the unpleasant push-up feeling is further alleviated.

In the above mattress, the apparent density of the first high resilience urethane foam layer is 25 to 35 kg / cm ³ and the hardness (40% compression) is 200 to 280 N / 314 cm ² . It is preferable that the apparent density is 20 to 60 kg / cm ³ and the hardness (40% compression) is 45 to 80 N / 314 cm ² .

According to this configuration, the density is low and the hardness is high, the body pressure dispersibility is excellent, and the unpleasant push-up feeling is alleviated. In addition, since the mattress can be lightened, the burden on the caregiver can be further reduced if it is used in a medical institution or a health facility.

In the above mattress, the first high resilience urethane foam layer preferably has a tensile strength of 150 to 240 kPa and a tear strength of 7 to 12 N / cm.

According to this configuration, a foam layer having sufficient strength can be formed even if profile processing is performed. For this reason, it is possible to provide a mattress excellent in durability that is not easily damaged even when a load is applied.

In the above mattress, a second high-rebound resilience urethane foam layer is laminated on the surface of the first high-rebound resilience urethane foam layer located on the opposite side of the profile processing surface, and the second high-rebound resilience urethane foam layer is disposed on the surface. The second low resilience urethane foam layer is preferably laminated.

According to this configuration, the body pressure dispersibility is particularly excellent, the unpleasant push-up feeling is further alleviated, and the strength can be further increased.

In the mattress, the resin film layer includes a side surface of the first low-rebound resilience urethane foam layer, a side surface of the first high-rebound resilience urethane foam layer, a side surface of the second high-rebound resilience urethane foam layer, and a second low-rebound resilience urethane. It is preferable to be laminated on the side surface and the surface of the foam layer.

According to this configuration, since all of the front and back surfaces and side surfaces of the mattress are covered with the resin film, the dirt can be easily wiped off even if dirt is attached to any surface. Moreover, since the sheets hung on the mattress are more difficult to shift, the labor of the assistant can be further reduced.

In the above mattress, the apparent density of the second high resilience urethane foam layer is 25 to 35 kg / cm ³ and the hardness (40% compression) is 120 to 170 N / 314 cm ² . It is preferable that the apparent density is 20 to 60 kg / cm ³ and the hardness (40% compression) is 45 to 80 N / 314 cm ² .

According to this configuration, in particular, the second high resilience urethane foam layer has a low density and a high hardness. For this reason, a mattress can be made still lighter. Thereby, if it uses in a medical institution, a health-care facility, etc., the burden of an assistant will be reduced.

In the above mattress, it is preferable that the compression residual strain (75% compression) of the second high resilience urethane foam layer is 2.5% or less.

According to this configuration, even if a load is applied over a long period of time, the mattress becomes difficult to sag. Therefore, favorable body pressure dispersibility, sleeping comfort, etc. can be maintained.

The cross-sectional view of a mattress provided with a first high resilience urethane foam layer, a first low resilience urethane foam layer, and a resin film layer. Provided on the front and back surfaces and side surfaces of the mattress, the first high resilience urethane foam layer, the first low resilience urethane foam layer, the second high resilience urethane foam layer, the second low resilience urethane foam layer, and the mattress. The cross-sectional view of a mattress provided with the made resin film layer. The perspective view of the mattress seen from the profile processing surface side of the 1st high resilience urethane foam layer. The map showing the body pressure distribution at the time of the body pressure dispersibility test start about the mattress surface near the 1st low resilience urethane foam layer. Map showing body pressure distribution 15 minutes after the start of the test. The map showing the body pressure distribution at the time of the body pressure dispersibility test start about the mattress surface near the 2nd low resilience urethane foam layer. Map showing body pressure distribution 15 minutes after the start of the test. The map showing the body pressure distribution at the time of the body pressure dispersibility test start about the mattress using a hard cotton cloth. Map showing body pressure distribution 15 minutes after the start of the test.

Hereinafter, an embodiment embodying the mattress of the present invention will be described with reference to FIGS.

The mattress of the present invention includes a first high resilience urethane foam layer (hereinafter referred to as “first high resilience elastic layer”) having a profile processed surface, and a first low resilience urethane foam layer ( (Hereinafter referred to as “first low-rebound resilience layer”) and at least a resin film layer laminated on the surface of the first low-rebound resilience layer. The thickness of the first low resilience elastic layer is 5 to 10 mm, and the moisture permeability (40 ° C.) of the resin film layer is 1000 to 1500 g / m ² · 24 h.

The first high resilience elastic layer 1 is formed using urethane foam having high resilience. A profile processed surface 11 is formed on the surface of the first high resilience elastic layer 1. The profile processing surface 11 is formed by inserting a urethane foam sheet between a pair of rolls having an uneven surface. The shape of the profile processing surface 11 is not particularly limited. For example, the profile processing surface 11 may be provided with a substantially conical convex portion 11a as shown in FIG. 3 or a substantially pyramidal convex portion. Further, the profile processing surface 11 may be provided with a convex portion having a substantially circular cross section extending in the width direction or the length direction of the mattress.

The rebound resilience of the first high rebound resilience layer 1 is not particularly limited, but the rebound resilience measured by JIS K 6400-3 (ISO 8307) is preferably 25 to 50%, preferably 30 to 45%. It is particularly preferred. If the rebound resilience of the first high resilience elastic layer 1 is 25 to 50%, excellent body pressure dispersibility can be obtained, and an unpleasant push-up feeling can be alleviated.

The apparent density of the first high resilience elastic layer 1 is not particularly limited, but the apparent density measured according to JIS K 7222 (ISO 845) is preferably 25 to 35 kg / m ³ , and preferably 25 to 30 kg / m ³ . It is particularly preferred. Also, the hardness of the first high resilience elastic layer 1 is not particularly limited, but the hardness at 40% constant compression measured by JIS K 6400-2 A method (ISO 2439) is 200 to 280 N / 314 cm ² . It is preferably 220 to 270 N / 314 cm ² . If the apparent density of the first high resilience elastic layer 1 is 25 to 35 kg / m ³ and the hardness is 200 to 280 N / 314 cm ² , excellent body pressure dispersibility can be obtained and the unpleasant push-up feeling can be alleviated. be able to. Also, the mattress can be lightened.

The strength of the first high resilience elastic layer 1 is not particularly limited, but the tensile strength (breaking strength) measured according to JIS K 6400-5 (ISO 1798) is preferably 150 to 240 kPa, and is preferably 170 to 220 kPa. It is particularly preferred. The tear strength measured according to JIS K 6400-5 (ISO 1798) is preferably 7 to 12 N / cm, and particularly preferably 8 to 11 N / cm. If the tensile strength of the first high resilience elastic layer 1 is 150 to 240 kPa and the tear strength is 7 to 12 N / cm, it has sufficient strength and is not easily damaged even when a load is applied.

The maximum thickness of the first high resilience elastic layer 1, that is, the height from the flat surface to the tip of the convex portion (see FIG. 3) is not particularly limited, but is preferably 20 to 40 mm, preferably 25 to 35 mm. It is particularly preferred. Further, the thickness of the base portion not subjected to profile processing and the height of the convex portion are not particularly limited, but the thickness of the base portion is preferably 12 to 22 mm, and preferably 15 to 19 mm. Particularly preferred. Further, the height of the convex portion is preferably 8 to 18 mm, and particularly preferably 11 to 15 mm.

The compression residual strain of the first high resilience elastic layer 1 is not particularly limited, but was measured by JIS K 6400-4 A method (ISO 3385) (75% compression of the test piece) in order to make the mattress difficult to sag. The compressive residual strain is preferably 3.5 to 7.5%, particularly preferably 4.0 to 6.5%. The first high resilience elastic layer 1 preferably has a predetermined compression residual strain from the viewpoint that it has a profile processed surface and can maintain a sufficient acupressure effect. Regarding the first high resilience elastic layer 1, the repeated compressive residual strain measured by JIS K 6400-4 A method (ISO 3385) is also not particularly limited, but is preferably 2.5% or less, and 2.0% or less. (Normally 0.5% or more) is particularly preferable.

The first low rebound resilience layer 2 is formed using urethane foam having a low rebound resilience. The thickness of the first low resilience elastic layer 2 is 5 to 10 mm, preferably 6 to 10 mm, and particularly preferably 7 to 9 mm. If the thickness of the first low resilience elastic layer 2 is 5 to 10 mm, it will not be easily damaged by a load. In addition, the body pressure dispersibility is excellent, and the sleeping comfort can be sufficiently improved.

The rebound resilience of the first low rebound resilience layer 2 is not particularly limited, but the rebound resilience measured by JIS K 6400-3 (ISO 8307) is preferably 5 to 15%, preferably 7 to 13%. It is particularly preferred. If the rebound resilience of the first low rebound resilience layer 2 is 5 to 15%, excellent body pressure dispersibility can be obtained, and an unpleasant push-up feeling can be alleviated.

The apparent density of the first low resilience elastic layer 2 is not particularly limited, but the apparent density measured according to JIS K 7222 (ISO 845) is preferably 20 to 60 kg / m ³ , and is preferably 30 to 50 kg / m ³ . It is particularly preferred. Further, the hardness of the first low-elasticity elastic layer 2 is not particularly limited, but the hardness at 40% constant compression measured by JIS K 6400-2 A method (ISO 2439) is 45 to 80 N / 314 cm ² . It is preferably 50 to 70 N / 314 cm ² . If the apparent density of the first low resilience layer 2 is 20 to 60 kg / m ³ and the hardness is 45 to 80 N / 314 cm ² , excellent body pressure dispersibility can be obtained and the unpleasant push-up feeling can be alleviated. be able to. Also, the mattress can be lightened.

The compressive residual strain of the first low resilience elastic layer 2 is not particularly limited, but in order to make the mattress difficult to set, it was measured by JIS K 6400-4 A method (75% compression of the test piece) (ISO 3385). The compression residual strain is preferably 4.0 to 8.0%, particularly preferably 4.5 to 7.0%. Regarding the first low resilience elastic layer 2, the repeated compressive residual strain measured by JIS K 6400-4 A method (ISO 3385) is also not particularly limited, but is preferably 2.0% or less, preferably 1.5% or less. (Normally 0.5% or more) is particularly preferable.

The resin film layer 3 is formed of a resin film made of a synthetic resin. Examples of the synthetic resin include a polyurethane resin, a polyolefin resin, a polyester resin, a polyamide resin, and the like. From the viewpoint of adhesiveness with a urethane foam layer such as the first low resilience elastic layer 2, a thermoplastic urethane resin film is preferable. If it is a thermoplastic urethane resin film, it can be easily and firmly bonded to the urethane foam layer by heating and pressing as required using an adhesive such as a solution type or emulsion type containing a polyurethane resin. Can be stacked. Furthermore, if it is a thermoplastic urethane resin film, it can be easily and firmly bonded and laminated to the urethane foam layer by frame lamination, thermal lamination or the like.

In particular, when the mattress 100 of the present invention is used on the bed of a care recipient in a medical institution or welfare facility, it is preferable that moisture due to perspiration or the like does not accumulate. For this reason, in order for the whole mattress 100 to have sufficient moisture permeability, the resin film layer 3 laminated on the surface of the first low resilience elastic layer 2 also needs to have predetermined moisture permeability. The moisture permeability of the resin film layer 3 measured according to JIS Z 0208 (ISO 2528) condition B (temperature: 40 ± 0.5 ° C., relative humidity: 90 ± 2%) is 1000 to 1500 g / m ² · 24 h. Are preferably 1050 to 1400 g / m ² · 24 h, particularly preferably 1100 to 1300 g / m ² · 24 h.

As described above, the resin film layer 3 has moisture permeability, but can suppress air leakage and maintain air pressure. For this reason, moisture does not accumulate in the mattress. Further, excellent body pressure dispersibility can be obtained, and sufficient cushioning properties can be obtained.

The thickness of the resin film layer 3 is not particularly limited, but in order for the resin film layer 3 to have sufficient cushioning properties in addition to the above moisture permeability, the thickness of the resin film layer 3 is 50 to 90 μm. Is preferable, and 60 to 80 μm is particularly preferable. When the thickness of the resin film layer 3 is 50 to 90 μm, moisture does not build up in the mattress and sufficient cushioning properties can be obtained. Moreover, since the resin film layer 3 has sufficient strength, the mattress can be prevented from being damaged.

Other physical properties of the resin film layer 3 are not particularly limited, but the tensile strength measured according to JIS K 7311 is preferably 45 to 90 MPa, and particularly preferably 60 to 80 MPa. When the tensile strength is 45 to 90 MPa, the resin film layer 3 is not easily damaged even when a load is applied. Therefore, the durability of the mattress is improved. The tensile elongation measured according to JIS K 7311 is preferably 450 to 750%, particularly preferably 500 to 700%. Furthermore, the tear strength measured according to JIS K 7311 is preferably 50 to 90 kN / m, and particularly preferably 60 to 80 kN / m.

Various additions such as flame retardants, antibacterial agents, antifungal agents, plasticizers, crosslinking agents, antioxidants, ultraviolet absorbers, light stabilizers, colorants, fillers, and the like in the film raw material of the resin film layer 3 An agent can also be blended. In particular, it is preferable to use a film raw material containing a flame retardant and an antibacterial agent. Thereby, the resin film layer 3 which has a flame retardance and antibacterial property can be formed, and the flame retardance and antibacterial property of a mattress improve. In particular, when used in a bed of a care recipient in a medical institution or welfare facility, the mattress is more preferably flame retardant and antibacterial from the viewpoint of fire caused by smoking, hygiene due to excrement, etc. .

Examples of the flame retardant include various flame retardants such as metal hydroxides such as aluminum hydroxide and phosphorus flame retardants such as phosphate esters. From the environmental viewpoint, phosphate-based flame retardants that do not contain halogens. A flame retardant is preferred. Examples of antibacterial agents include zeolite antibacterial agents such as silver zeolite, silica gel antibacterial agents such as complexed silver and silica gel, and various antibacterial agents such as calcium phosphate antibacterial agents. One type of each flame retardant and antibacterial agent may be used, or two or more types may be used in combination.

As shown in FIG. 1, the mattress 100 of the present invention includes a first high resilience elastic layer 1, a first low resilience elastic layer 2, and a resin film layer 3. According to the present invention, since only these three layers have sufficient body pressure dispersibility and the like, it is possible to provide a mattress 100 with good sleeping comfort. In particular, when used in a bed of a care recipient in a medical institution or welfare facility, it is required to further improve the body pressure dispersibility and comfort of the mattress. Therefore, as shown in FIG. 2, in addition to the above three layers, the mattress 200 has a second high resilience urethane foam layer on the surface of the first high resilience elastic layer 1 located on the side opposite to the profile processed surface 11. (Hereinafter referred to as “second high resilience elastic layer”) 4 and a second low resilience urethane foam layer (hereinafter referred to as “second low resilience elastic layer”) on the surface of the second high resilience elastic layer 4. 5 is preferably provided.

The apparent density of the second high resilience elastic layer 4 is not particularly limited, but the apparent density measured according to JIS K 7222 (ISO 845) is preferably 25 to 35 kg / m ³ , and is 27 to 33 kg / m ³ . It is particularly preferred. Further, the hardness of the second high resilience elastic layer 4 is not particularly limited, but the hardness at 40% constant compression measured by JIS K 6400-2 A method (ISO 2439) is 120 to 170 N / 314 cm ² . It is preferably 130 to 160 N / 314 cm ² . If the apparent density of the second high impact resilience layer 4 is 25 to 35 kg / m ³ and the hardness is 120 to 170 N / 314 cm ² , the mattress can be made even lighter. Therefore, if the mattress 200 is used in a hospital, a health facility or the like, the burden on the assistant can be reduced.

Furthermore, it is preferable that the second high resilience elastic layer 4 is a urethane foam layer that is particularly difficult to sag. For this reason, the compression residual strain measured by JIS K 6400-4 A method (75% compression of the test piece) (ISO 3385) is preferably 2.5% or less, and 2.0% or less (usually 1 0.0% or more) is particularly preferable. If the compressive residual strain of the second high resilience elastic layer 4 is 2.5% or less, excellent body pressure dispersibility and good sleeping comfort can be maintained over a long period of time. Regarding the second highly repulsive elastic layer 4, the repetitive compressive residual strain measured by JIS K 6400-4 A method (ISO 3385) is also preferably 2.0% or less, and 1.5% or less (usually 0.00. 5% or more) is particularly preferable.

The rebound resilience of the second high rebound resilience layer 4 is not particularly limited, but the rebound resilience measured by JIS K 6400-3 (ISO 8307) is preferably 30 to 70%, preferably 40 to 60%. It is particularly preferred. When the rebound resilience of the second high resilience layer 4 is 30 to 70%, the body pressure dispersibility is further improved, and the unpleasant push-up feeling can be further alleviated. Further, the thickness of the second high resilience elastic layer 4 is not particularly limited, but is preferably 20 to 40 mm, and particularly preferably 25 to 35 m.

The apparent density of the second low impact resilience layer 5 is not particularly limited, but the apparent density measured according to JIS K 7222 (ISO 845) is preferably 20 to 60 kg / m ³ , and is preferably 30 to 50 kg / m ³ . It is particularly preferred. Further, the hardness of the second low resilience elastic layer 5 is not particularly limited, but the hardness at 40% constant compression measured by JIS K 6400-2 A method (ISO 2439) is 45 to 80 N / 314 cm ² . It is preferably 50 to 70 N / 314 cm ² . If the apparent density of the second low resilience elastic layer 5 is 20 to 60 kg / m ³ and the hardness is 45 to 80 N / 314 cm ² , excellent body pressure dispersibility can be obtained, and unpleasant push-up feeling can be alleviated. be able to.

The rebound resilience of the second low rebound resilience layer 5 is not particularly limited, but the rebound resilience measured by JIS K 6400-3 (ISO 8307) is preferably 5 to 15%, and is 7 to 13%. It is particularly preferred. If the impact resilience is 5 to 15%, excellent body pressure dispersibility can be obtained, and unpleasant push-up feeling can be alleviated. Also, the thickness of the second low-rebound elastic layer 5 is not particularly limited, but is preferably 10 to 30 mm, and particularly preferably 15 to 25 mm. Since the desired physical properties are common to the first low-elasticity elastic layer 2 and the second low-elasticity elastic layer 5, the first and second low-elasticity

elastic layers

2 and 5 are formed using the same grade of urethane foam. May be.

The compression residual strain of the second low-rebound resilience layer 5 is not particularly limited, but in order to form a mattress that is difficult to loosen, according to JIS K 6400-4 A method (75% compression of the test piece) (ISO 3385) The measured compressive residual strain is preferably 4.0 to 8.0%, particularly preferably 5.0 to 7.0%. Further, the repeated compressive residual strain of the first low resilience elastic layer 2 measured by JIS K 6400-4 A method (ISO 3385) is not particularly limited, but is preferably 2.0% or less, 1.5 % Or less (usually 0.5% or more) is particularly preferable.

The resin film layer 3 is laminated on at least the surface of the first low resilience elastic layer 2. In addition, the resin film layer 3 includes a side surface of the first low-repulsive elastic layer 2, a side surface of the first high-repulsive elastic layer 1, a side surface of the second high-repulsive elastic layer 4, and a side surface of the second low-repulsive elastic layer 5. And it is preferable to be laminated on the surface. That is, the resin film layer 3 is preferably laminated on all of the front and back surfaces and side surfaces of the mattress 200. If it is this form, even if dirt adheres to any surface of mattress 200, the dirt can be easily wiped off. Moreover, since the sheets hung on the mattress 200 are difficult to slip, the labor of the assistant can be further reduced.

The mattress 200 can also be used with the first low-rebound resilience layer 2, that is, the profile processing surface facing upward, and the second low rebound resilience layer 5, that is, the flat surface without the profile processing surface is facing upward. You can also. When a flat surface having no profile processing surface is used facing upward, the body pressure dispersibility is further improved, and floor rubbing or the like can be further suppressed. Therefore, it is particularly useful for nurses who cannot turn over and so on. On the other hand, when the profile processed surface is used facing upward, the acupuncture points 11a shown in FIG. 3 stimulate the acupoints, and the acupressure effect can be achieved. For this reason, it is particularly useful for those who can move by themselves, such as turning over.

The first high rebound resilience layer 1, the first low rebound resilience layer 2, the second high rebound resilience layer 4 and the second low rebound resilience layer 5 contain various polyols, polyisocyanates, catalysts, foam stabilizers and foaming agents. It is formed of a flexible urethane foam obtained by reacting and curing a foam raw material. The raw materials are appropriately selected and used according to the required physical properties such as the rebound resilience, apparent density, hardness and the like of each layer. Moreover, it does not specifically limit as a manufacturing method of a flexible urethane foam, The normal method in this technical field is employable. For example, a flexible urethane slab foam is produced by using the above-mentioned foam raw material and reacting and curing by a one-shot method. And the foam sheet of a predetermined dimension is cut out from the obtained slab foam, and each said layer is formed.

In addition to the essential components described above, the foam raw materials include various flame retardants, antibacterial agents, antifungal agents, plasticizers, crosslinking agents, antioxidants, ultraviolet absorbers, light stabilizers, colorants, fillers, and the like. These additives can also be blended. In particular, in medical institutions or welfare facilities, it is more preferable to use a flame retardant and antibacterial mattress from the viewpoints of fire caused by smoking, hygiene due to excrement, and the like. Therefore, it is preferable to use a foam raw material containing various flame retardants and antibacterial agents.

The laminating method of each foam sheet for forming the first high rebound elastic layer 1, the first low rebound elastic layer 2, the second high rebound elastic layer 4, and the second low rebound elastic layer 5 is not particularly limited. For example, they can be bonded and laminated by a method such as frame lamination or thermal lamination. In addition, after applying an adhesive such as a solution type or emulsion type containing polyurethane resin to the required surface of each foam sheet, the foam sheets are joined and laminated by heating and pressing as necessary. You can also.

Hereinafter, the present invention will be specifically described by way of examples.

Example 1
First, a flexible urethane slab foam for forming each of the first high-repulsion elastic layer 1, the first low-repulsion elastic layer 2, the second high-repulsion elastic layer 4, and the second low-repulsion elastic layer 5 is used by a conventional method. , Each manufactured. Thereafter, from each slab foam, a foam sheet having a thickness of 30 mm to be the first high-repulsive elastic layer 1, a foam sheet having a thickness of 8 mm to be the first low-repulsive elastic layer 2, and a thickness to be the second high-repulsive elastic layer 4 A 30 mm foam sheet and a 20 mm thick foam sheet serving as the second low resilience elastic layer 5 were cut out. Next, a profile sheet was formed by inserting a foam sheet having a thickness of 30 mm to be the first high resilience elastic layer 1 between a pair of rolls having an uneven surface. Thereby, the processed sheet which has a convex part of height 13mm on the whole surface was obtained. Each foam sheet had a width of 830 mm and a length of 1910 mm. The physical properties of each foam sheet were measured by the above methods. The results are shown in Table 1.

Thereafter, an emulsion type adhesive containing a polyurethane resin was sprayed on each bonding surface of the foam sheet to be the first high resilience elastic layer 1 and the foam sheet to be the second high resilience elastic layer 4. Subsequently, the adhesive was dried to remove the medium. And two foam sheets were joined and the lamination sheet was produced. Next, both surfaces of the laminated sheet, the foam sheet serving as the first low-rebound resilience layer 2 and the bonding surface of the foam sheet serving as the second low-rebound resilience layer 5 were heated. And each foam sheet was laminated | stacked and it heat-seal | bonded by pressing. Thus, a laminate composed of the first high repulsion elastic layer 1, the first low repulsion elastic layer 2, the second high repulsion elastic layer 4, and the second low repulsion elastic layer 5 was produced.

An adhesive was sprayed on all of the front and back surfaces and side surfaces of the laminate. Subsequently, the adhesive was dried to remove the medium. Subsequently, a 70 μm-thick thermoplastic urethane resin film extruded by T-die molding was brought into close contact with the entire surface of the laminate and heated. And the laminated body and the resin film were joined and the resin film layer 3 was formed. The moisture permeability of the resin film was 1200 g / m ² · 24 h, the tensile strength was 72 MPa, the tensile elongation was 600%, and the tear strength was 68 kN / m.

The mattress 200 of FIG. 2 thus manufactured was placed on the test surface of a pressure measuring device (model “FSA” manufactured by VISTA Medical). Next, a subject (male, 50 years old, height: 177 cm, weight: 70 kg) was laid on his / her back on the mattress 200. The body pressure distribution was measured immediately after the subject lay down and after 15 minutes. The body pressure distribution was measured with the subject lying on the mattress 200 with the first low resilience elastic layer 2 facing upward. FIG. 4 shows the body pressure distribution immediately after lying down, and FIG. 5 shows the body pressure distribution after 15 minutes. The body pressure distribution was measured even when the subject lay on the mattress 200 with the second low-rebound resilience layer 5 facing upward. FIG. 6 shows the body pressure distribution immediately after lying down, and FIG. 7 shows the body pressure distribution after 15 minutes. In addition, body pressure distribution was also measured for a mattress using a conventional polyester hard cotton cloth (product name “Paracare Mattress”, manufactured by Paramount Bed Co., Ltd.) by the same method. FIG. 8 shows the body pressure distribution immediately after lying down, and FIG. 9 shows the body pressure distribution after 15 minutes.

4 to 9, it is shown that the pressure applied to each part increases in the order of the white part, the small dot part, the large dot part, the hatched part, the lattice part, and the black part. Therefore, as the pattern closer to the black portion is larger, there are more portions where the pressure is locally increased, and the body pressure dispersibility is inferior. On the other hand, the more patterns near the white part, the smaller the number of sites where the pressure is locally increased, and the better the body pressure dispersibility.

4 and 5, when the subject lay down on the mattress 200 with the profile processing surface facing upward, almost no pressure concentration on the head, upper back, and buttocks was observed immediately after lying down. In FIG. 4, almost the whole was a white portion, a small dot portion, and a large dot portion. From this, it can be seen that the body pressure (weight) of the subject is almost completely dispersed. Further, in this case, the first low repulsion elastic layer 2 is as thin as 8 mm, the core material (first high repulsion elastic layer 1) is high repulsion, and has a profile processed surface. For this reason, as shown in the shaded part in FIG. 4, although higher body pressure is concentrated on the head and buttocks than when the subject lies on the mattress 200 with the flat surface facing upward, Not really. Furthermore, as shown by the shaded area in FIG. 5, after 15 minutes, body pressure concentration slightly progresses to the head, upper back and buttocks, but this is not a problem. In addition, as shown in the small dot portion and the large dot in FIG. 5, immediately after the subject lies down, the body pressure spreads to the waist where pressure was not applied, so the burden on the subject's waist is also reduced. Yes.

Further, according to FIGS. 6 and 7, when the subject lay on the mattress 200 with the flat surface facing upward, the pressure concentration on the upper back and the buttocks was not observed immediately after lying down. In FIG. 6, the whole is a white portion, a small dot portion, and a large dot portion. From this, it can be seen that the body pressure of the subject is completely dispersed. As shown in the small dot portion of FIG. 6, body pressure dispersion to the waist is slightly observed immediately after lying down. Moreover, as shown by the large dot portion and the shaded portion in FIG. 7, after a lapse of 15 minutes, body pressure concentration on the head, upper back, and buttocks is slightly observed, but this is not a problem. Moreover, as shown by the small dot portion and the large dot in FIG. 7, the body pressure dispersion proceeds at the waist where the body pressure dispersion was observed immediately after the subject lay down. For this reason, a flat surface having excellent body pressure dispersibility is particularly useful for nurses who cannot turn over.

On the other hand, as shown in the hatched portion, the lattice portion, and the black portion in FIG. 8, in the mattress using the conventional hard cotton cloth, pressure concentration is observed in the upper back and the buttocks, particularly the buttocks immediately after the subject lies down. In addition, almost no pressure is applied to the waist, and a burden of body pressure is applied to the waist. Furthermore, as shown by the hatched portion and the lattice portion in FIG. 9, after 15 minutes have passed, the pressure concentration on the head and upper back progresses, while little pressure is still applied to the waist. From this, the body pressure dispersibility of the conventional mattress is inferior to that of the present invention.

The resin film layer 3 is formed of a thermoplastic urethane resin film containing an antibacterial agent. The antibacterial properties were measured and evaluated by the bacterial solution absorption method of JIS L 1902 (ISO 20743). As a result, the bacteriostatic activity value was 4.5 when the bacterial species was MRSA, and the bacteriostatic activity values were all 5.0 or more when they were green-concentrated bacteria, Klebsiella pneumoniae, and Staphylococcus aureus. That is, the bacteriostatic activity value is 2.2 or more for any bacterial species, which is suitable. Therefore, it has excellent antibacterial performance.

The present invention can be used in the technical field of mattresses used in various beds, particularly hospitals, health facilities and the like.

Claims

A first high-rebound resilience urethane foam layer having a profile processed surface, a first low-rebound resilience urethane foam layer stacked on the profile-processed surface, and a resin stacked on the surface of at least the first low rebound elastic urethane foam layer A mattress comprising a film layer,
The first low resilience urethane foam layer has a thickness of 5 to 10 mm;
The mattress characterized in that the resin film layer has a moisture permeability (40 ° C.) of 1000 to 1500 g / m 2 · 24 h.
The mattress according to claim 1,
The first high resilience urethane foam layer has a rebound resilience of 30 to 50%;
The mattress characterized in that the first low resilience urethane foam layer has a resilience modulus of 5 to 15%.
The mattress according to claim 1 or 2,
The apparent density of the first high resilience urethane foam layer is 25 to 35 kg / cm 3 , and the hardness (40% compression) is 200 to 280 N / 314 cm 2 ;
The mattress characterized in that the first low resilience urethane foam layer has an apparent density of 20 to 60 kg / cm 3 and a hardness (40% compression) of 45 to 80 N / 314 cm 2 .
The mattress according to any one of claims 1 to 3,
A mattress wherein the first high resilience urethane foam layer has a tensile strength of 150 to 240 kPa and a tear strength of 7 to 12 N / cm.
The mattress according to any one of claims 1 to 4,
A second high-rebound resilience urethane foam layer is laminated on the surface of the first high-rebound resilience urethane foam layer located on the opposite side of the profile processing surface;
A mattress, wherein a second low resilience urethane foam layer is laminated on a surface of the second high resilience urethane foam layer.
The mattress according to claim 5,
The resin film layer includes a side surface of the first low-rebound resilience urethane foam layer, a side surface of the first high-rebound resilience urethane foam layer, a side surface of the second high-rebound resilience urethane foam layer, and the second low-rebound resilience urethane. A mattress that is laminated on a side surface and a surface of a foam layer.
The mattress according to claim 5 or 6,
The second high resilience urethane foam layer has an apparent density of 25 to 35 kg / cm 3 and a hardness (40% compression) of 120 to 170 N / 314 cm 2 ;
The mattress characterized in that the second low-resilience urethane foam layer has an apparent density of 20 to 60 kg / cm 3 and a hardness (40% compression) of 45 to 80 N / 314 cm 2 .
The mattress according to any one of claims 5 to 7,
The mattress characterized in that the compression residual strain (75% compression) of the second high resilience urethane foam layer is 2.5% or less.