WO2022097435A1 - クッション体およびその製造方法 - Google Patents

クッション体およびその製造方法 Download PDF

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Publication number
WO2022097435A1
WO2022097435A1 PCT/JP2021/037855 JP2021037855W WO2022097435A1 WO 2022097435 A1 WO2022097435 A1 WO 2022097435A1 JP 2021037855 W JP2021037855 W JP 2021037855W WO 2022097435 A1 WO2022097435 A1 WO 2022097435A1
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WO
WIPO (PCT)
Prior art keywords
region
repulsive force
cushion
cushion body
filament
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2021/037855
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English (en)
French (fr)
Japanese (ja)
Inventor
晃 水野
佑輔 林
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Airweave Inc
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Airweave Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Airweave Inc filed Critical Airweave Inc
Priority to US18/035,110 priority Critical patent/US12557928B2/en
Priority to EP21888988.9A priority patent/EP4241626B1/en
Priority to JP2022560689A priority patent/JPWO2022097435A1/ja
Publication of WO2022097435A1 publication Critical patent/WO2022097435A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/10—Pillows
    • A47G9/1081—Pillows comprising a neck support, e.g. a neck roll
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/10—Pillows
    • A47G9/1081—Pillows comprising a neck support, e.g. a neck roll
    • A47G9/109—Pillows comprising a neck support, e.g. a neck roll adapted to lie on the side and in supine position
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion

Definitions

  • the present invention relates to a cushion body that supports the head of a user in a sleeping posture, and a method for manufacturing the same.
  • Patent Documents 1 and 2 disclose a filament three-dimensional coupler obtained by three-dimensionally fusion-bonding a filament made of a thermoplastic resin, and a method for producing the filament. Since the filament three-dimensional conjugate has a high repulsive force, it does not easily lose its shape, has good air permeability, and is easy to wash with water, so that it is also excellent in that it can be used cleanly.
  • the filament obtained by three-dimensionally fusion-bonding the filament made of thermoplastic resin In order for the user to get a comfortable sleep, it is important to stabilize the head position of the user in the sleeping posture, but the filament obtained by three-dimensionally fusion-bonding the filament made of thermoplastic resin.
  • a three-dimensional composite is used as a cushion material for pillows, there is a problem that the position of the head (tilt of the head) becomes unstable due to the high repulsive force, and as a cushion body for pillows, the head is moderately used.
  • a cushion body that can stabilize the head position while sinking is desired.
  • an object of the present invention is to provide a cushion body capable of stabilizing the head position while appropriately sinking the head, and a method for manufacturing the cushion body.
  • the cushion body according to the present invention is a cushion body for pillows formed of a filament three-dimensional bond obtained by three-dimensionally fusion-bonding filaments made of a thermoplastic resin, and is on both ends in the width direction.
  • the repulsive force in the region is higher than the repulsive force in the central region, and the repulsive force in the regions on both ends in the depth direction is higher than the repulsive force in the central region. According to this configuration, it is possible to stabilize the position of the head while appropriately sinking the head without impairing the difficulty of losing its shape, good breathability, and cleanliness.
  • the cushion portion in which the repulsive force in the region on both ends in the width direction is higher than the repulsive force in the region in the central portion, and the repulsive force in the region on both ends in the depth direction are in the central portion.
  • At least two types of cushion portions including the cushion portion having a repulsive force higher than the repulsive force of the region may be laminated in the vertical direction.
  • the configuration may be formed by inserting the second cushion portion into the inside of the first cushion portion formed in a substantially cylindrical shape.
  • the manufacturing method according to the present invention is a manufacturing method for manufacturing a cushion body having the above configuration, which is a three-dimensional filament coupling, and comprises a molten filament supply process in which a molten filament group is discharged downward from a plurality of openings of a nozzle portion. , A fusion bond forming process in which the discharged molten filament group is cooled and fusion-bonded, and the fusion-bonded bonded body is drawn in the transport direction, and the diameter dimension or the density of the opening is included. A method in which the degree is changed for each different region of the nozzle portion, and the repulsive force for each different region of the cushion body is changed by changing the pulling speed at predetermined time intervals. do.
  • the pillow according to the present invention it is possible to stabilize the head position while appropriately sinking the head.
  • the vertical direction (height direction), the left-right direction (width direction), and the front-back direction (depth direction) of the pillow cushion body are as shown in FIG.
  • the depth direction of the pillow coincides with the height direction of the user who is lying on his back
  • the width direction of the pillow coincides with the left-right direction of the user.
  • FIG. 1 is a schematic plan view (upper viewpoint view) of the cushion body 101 for a pillow according to the first embodiment
  • FIG. 2 is a cross section of the cushion body 101 when cut in a plane divided into left and right. It is a figure.
  • the cushion body 101 is formed so as to support the head of the user in the sleeping posture.
  • the broken line shown in FIG. 1 indicates the approximate position of the user's head.
  • the cushion body 101 is formed in a substantially rectangular shape with the left and right sides in the longitudinal direction when viewed upward, and is mainly used so that the central region of the upper surface supports the head. Further, the cushion body 101 may be used as a pillow in a state of being covered with a pillow cover (not shown).
  • the cushion body 101 is a filament three-dimensional bonded body obtained by three-dimensionally fusion-bonding filaments made of a thermoplastic resin.
  • the filament three-dimensional conjugate increases the repulsive force by thickening the filament forming the filament (increasing the filament diameter) and increasing the number of filaments per unit volume (increasing the density of filaments). It is possible to make it higher.
  • the repulsive force in the region on both ends in the left-right direction is higher than the repulsive force in the region in the central portion, and the repulsive force in the region on both ends in the front-rear direction is also in the region in the central portion. It is higher than the repulsive force.
  • the cushion body 101 is set with a repulsive force arrangement pattern (relationship between each region divided in the upward view and the repulsive force). ..
  • FIG. 1 (the same applies to FIGS. 2, 5 to 8 and 10 described later), it is shown that the darker the color, the higher the repulsive force.
  • the repulsive force of the cushion body 101 is substantially uniform in the vertical direction.
  • the cushion body 101 is divided into 5 equal parts on the left and right and 3 equal parts on the front and back, and is divided into a total of 15 regions, and the central region thereof is set as the region Sa having the lowest repulsive force. Further, the four regions adjacent to each other on the front, back, left, and right sides of the region Sa are set in the region Sb having the next highest repulsive force after the region Sa. Further, the four regions at the four corners are set to the region Sd having the highest repulsive force. The remaining six regions are set to regions Sc having a higher repulsive force than the region Sb and a lower repulsive force than the region Sd.
  • the repulsive force of the cushion body in this embodiment is changed in three stages from the center of the upward view to each of the left and right ends, and is changed in two stages in each of the front and rear ends. Not particularly limited.
  • the cushion body 101 is formed so that the repulsive force is set low in the region in the center of the upward view and the head of the user can be appropriately submerged.
  • the cushion body 101 has a higher repulsive force in the regions on both ends in the left-right direction and the regions on both ends in the front-rear direction than the region in the center of the upward view.
  • the head is less likely to sink in the area on both ends in the anteroposterior direction. As a result, the position of the head of the user can be stabilized as much as possible at the position near the center of the upward view of the cushion body 101, and the user can obtain a comfortable sleeping comfort.
  • the temporal region of the user in the lateral decubitus position can be supported in the areas on both ends in the left-right direction and on both ends in the front-back direction, and it is possible to suppress excessive sinking of the head as much as possible. ..
  • the cushion body 101 the height of the pillow in the position supporting the back of the head and the height of the pillow in the position supporting the cervical spine can be freely changed in the supine position. Preventing it, the user can sleep in a posture close to the natural body.
  • the heights of the pillows on both ends in the left-right direction and on both ends in the front-back direction can be freely changed, and the user can sleep in a posture close to a natural body when lying down.
  • the cushioning property of the peripheral edge of the cushion body is relatively easily deteriorated by the load, but in the present embodiment, the head is prevented from moving onto the peripheral edge of the cushion body as much as possible, and the cushion body is less likely to be deteriorated. It is possible to do.
  • the region Sb on the rear side of the cushion body 101 has a higher repulsive force than the region Sa in the center. Therefore, the cushion body 101 can support the area around the cervical spine of the user with a portion having a relatively high repulsive force, suppress excessive sinking of the back of the head, and give the user a comfortable sleeping comfort.
  • FIG. 3A is a schematic front view of the cushion body 102 for a pillow according to the second embodiment
  • FIG. 4 is a cross-sectional view of the cushion body 102 when cut in a plane divided into left and right.
  • the cushion body 102 is formed to support the head of a user in a sleeping posture, and is mainly used so that the central region of the upper surface, which is substantially rectangular, supports the head.
  • the cushion body 102 has a configuration in which cushion portions having different repulsive force arrangement patterns (relationship between each region divided in upward view and the repulsive force) are laminated in the vertical direction. More specifically, the cushion body 102 is laminated so that the upper cushion portion 121, the middle cushion portion 122, and the lower cushion portion 123 are arranged in order from the top.
  • the cushion body 102 is formed by vertically superimposing the cushion portions 121 to 123, which are separately formed filament three-dimensional coupling bodies. However, the cushion body 102 may be integrated by adhering or fusing the cushion portions 121 to 123.
  • the upper cushion portion 121 is set with a repulsive force arrangement pattern as shown in the colored state in FIG. That is, the upper cushion portion 121 is divided into 5 equal parts on the left and right and 3 equal parts on the front and back, and is divided into a total of 15 regions, and the central region thereof is set as the region Sa having the lowest repulsive force. Further, the four regions adjacent to each other on the front, back, left, and right sides of the region Sa are set in the region Sb having the next highest repulsive force after the region Sa. Further, the four regions at the four corners are set to the region Sd having the highest repulsive force. The remaining six regions are set to regions Sc having a higher repulsive force than the region Sb and a lower repulsive force than the region Sd.
  • the middle cushion portion 122 is set with a repulsive force arrangement pattern as shown in the colored state in FIG. That is, the middle cushion portion 122 is divided into five regions on the left and right, and is divided into a total of five regions, and the left-right dimension of the regions at both left and right ends is about half of the left-right dimension of the other three regions.
  • the central region is set to the region Sa with the lowest repulsive force, the regions on both sides of it are set to the region Sd with the highest repulsive force, and the regions at both left and right ends are set to the region Sc with lower repulsive force than the region Sd. ing.
  • the lower cushion portion 123 has a repulsive force arrangement pattern set as shown in the colored state in FIG. 7. That is, the lower cushion portion 123 is divided into three regions in the front-rear direction and divided into a total of three regions, and the front-rear direction dimension of the front-rear and rear-end regions is about half of the front-rear direction dimension of the central region.
  • the central region is set to the region Sa having the lowest repulsive force, and the regions on both the front and rear sides are set to the region Sd having the highest repulsive force.
  • the repulsive force of each of the cushion portions 121 to 123 is generally uniform in the vertical direction.
  • the cushion body 102 has such cushion portions 121 to 123, and the cushion body 102 as a whole has a repulsive force in the region on both ends in the left-right direction, which is higher than the repulsive force in the region in the central portion.
  • the repulsive force in the regions on both ends is higher than the repulsive force in the central region. Therefore, the position of the head of the user can be stabilized as much as possible at the position near the center of the upward view of the cushion body 102, and the user can obtain a comfortable sleeping comfort.
  • the cushion body 102 can give a complicated tactile sensation to the user by laminating the cushion portions 121 to 123 having different repulsive force arrangement patterns.
  • the specific arrangement pattern of the repulsive force in each cushion portion 121 to 123 may be variously changed according to, for example, the preference of the user.
  • the arrangement pattern of the upper cushion portion 121 may be set as shown in the colored state in FIG. In this example, the upper cushion portion 121 is divided into five equal parts on the left and right, the central region is set to the region Sa having the lowest repulsive force, and the region having a higher repulsive force is assigned toward both left and right ends.
  • FIG. 3B is a schematic front view of the cushion body 202 which is a modification of the cushion body 102 according to the second embodiment.
  • the cushion body 202 is used so that the height of both ends in the front-rear direction (depth direction) is higher than the height of the central portion, and the central region of the upper surface, which is mainly substantially rectangular, supports the head.
  • the cushion body 202 has a structure in which cushion portions having different repulsive force arrangement patterns (relationship between each region divided in upward view and the repulsive force) are laminated in the vertical direction. More specifically, in the cushion body 202, the upper cushion portion 221, the middle cushion portion 222, and the lower cushion portion 223 are laminated so as to be arranged in order from the top.
  • the arrangement pattern of the repulsive force of the upper cushion portion 221 is the same as that of the upper cushion portion 121
  • the arrangement pattern of the repulsive force of the middle cushion portion 222 is the same as that of the middle cushion portion 122
  • the cushion body 202 is formed by vertically superimposing the cushion portions 221 to 223, which are separately formed filament three-dimensional coupling bodies. However, the cushion body 202 may be integrated by adhering or fusing the cushion portions 221 to 223.
  • FIG. 9A is a schematic front view of the cushion body 103 for a pillow according to the third embodiment.
  • the second cushion portion 132 of a substantially rectangular parallelepiped is inserted into the inside of the first cushion portion 131 formed in a cylindrical shape with the upper surface 103a and the lower surface 103b as a part of the side surface. It is formed.
  • the first cushion portion 131 is formed in a cylindrical shape with the left and right axes as axes, and the internal space is open on both the left side and the right side.
  • the cushion body 131 may be formed in the shape of a bottomed cylinder in which the left side or the right side of the internal space is closed, or may be formed in the shape of a cylinder whose axial direction is the front-rear direction instead of the left-right direction.
  • the cushion body 103 is formed to support the head of a user in a sleeping posture, and is mainly used so that the central region of the upper surface, which is a substantially rectangular shape, supports the head.
  • the first cushion portion 131 and the second cushion portion 132 are filament three-dimensional couplings formed separately.
  • FIG. 10 is a schematic plan view of the first cushion portion 131.
  • the first cushion portion 131 is set with a repulsive force arrangement pattern. That is, the first cushion portion 131 is divided into 5 equal parts on the left and right and 3 equal parts on the front and back, and is divided into a total of 15 regions, and the central region thereof is set as the region Sa having the lowest repulsive force. Further, the four regions adjacent to each other on the front, back, left, and right sides of the region Sa are set in the region Sb having the next highest repulsive force after the region Sa. Further, the four regions at the four corners are set to the region Sd having the highest repulsive force. The remaining six regions are set to regions Sc having a higher repulsive force than the region Sb and a lower repulsive force than the region Sd.
  • the repulsive force of the first cushion portion 131 is substantially uniform in the vertical direction.
  • FIG. 11 is a schematic plan view of the second cushion portion 132.
  • the second cushion portion 132 is formed in a substantially plate shape whose shape and dimensions are set to fit the internal space of the first cushion portion 131. Further, the second cushion portion 132 has a substantially uniform repulsive force as a whole, but a hole 132a is formed at a position in the center of the upward view.
  • the hole 132a may be a through hole or may be in the form of a recess opened only on the upper side.
  • the cushion body 103 formed by inserting the second cushion portion 132 into the internal space of the first cushion portion 131 has a substantially smaller repulsive force at a position corresponding to the hole 132a, and the user's head sinks. It becomes easy to get in. This makes it easier to settle the user's head position to that position.
  • the size and position of the hole 132a in the second cushion portion 132 may be appropriately adjusted according to the head shape and preference of each individual user.
  • FIG. 9B is a schematic front view of the cushion body 203 which is a modification of the cushion body 103 according to the third embodiment.
  • the second cushion portion 232 of a substantially rectangular parallelepiped is inserted into the inside of the first cushion portion 231 formed in a cylindrical shape with the upper surface 203a and the lower surface 203b as a part of the side surface. It is formed.
  • the first cushion portion 231 is formed in a cylindrical shape centered on the left and right, and the internal space opens on both the left side and the right side, and the height on both ends in the front-rear direction (depth direction). Is higher than the height of the central part.
  • the repulsive force in the region on both ends in the width direction is higher than the repulsive force in the region on the central portion
  • the repulsive force in the region on both ends in the depth direction is the repulsive force in the region on the central portion. It is higher than the force.
  • the repulsive force in the region on both ends in the width direction is higher than the repulsive force in the region on the central portion
  • the repulsive force in the region on both ends in the depth direction is higher than the repulsive force in the region on the central portion. Is also getting higher.
  • the first cushion portion 231 may be formed in the shape of a bottomed cylinder in which the left side or the right side of the internal space is closed, or may be formed in the shape of a cylinder whose axial direction is the front-rear direction instead of the left-right direction.
  • cushion bodies 101 of the first embodiment described above and the cushion portions 121 to 123, 131, 132 of the second and third embodiments (hereinafter referred to as cushion bodies).
  • a manufacturing apparatus and a manufacturing method of a filament three-dimensional bonded body that can be used as (sometimes collectively referred to as X) will be described.
  • FIG. 12 is a configuration diagram of a filament three-dimensional conjugate manufacturing apparatus 1.
  • FIG. 13 is a cross-sectional view taken along the line AA'shown in FIG.
  • the vertical, horizontal, and front-back directions (directions orthogonal to each other) with respect to the manufacturing apparatus 1 are as shown in these figures. Each of these directions is merely defined for convenience so that the vertical direction is the vertical direction and the pair of receiving plates 30 to be described later face each other in the front-rear direction.
  • the filament three-dimensional coupling manufacturing apparatus 1 has a three-dimensional molten filament group MF and a molten filament supply unit 10 that discharges a molten filament group MF composed of a plurality of molten filaments having a diameter of 0.5 mm to 3 mm downward in the vertical direction. It is provided with a fusion bond forming portion 20 that is entangled with each other to fuse and bond the contact points, and then cooled and solidified to form a filament three-dimensional bond 3DF.
  • the molten filament supply unit 10 includes a pressure melting unit 11 (extruder) and a filament discharging unit 12 (die).
  • the pressure melting unit 11 includes a material charging unit 13 (hopper), a screw 14, a screw motor 15 for driving the screw 14, a screw heater 16, and a plurality of temperature sensors (not shown). Inside the pressure melting section 11, a cylinder 11a for transporting the thermoplastic resin supplied from the material charging section 13 while being heated and melted by the screw heater 16 is formed.
  • the screw 14 is rotatably housed in the cylinder 11a.
  • a cylinder discharge port 11b for discharging the thermoplastic resin toward the filament discharge portion 12 is formed.
  • the heating temperature of the screw heater 16 is controlled based on, for example, a detection signal of a temperature sensor provided in the molten filament supply unit 10.
  • the filament discharge section 12 includes a nozzle section 17, a die heater 18, and a plurality of temperature sensors (not shown), and inside, a guide flow path 12a for guiding the molten thermoplastic resin discharged from the cylinder discharge port 11b to the nozzle section 17 is provided. It is formed.
  • the nozzle portion 17 is a substantially rectangular parallelepiped metal thick plate in which a plurality of openings are formed, and is provided at the lower part of the filament discharge portion 12 which is the most downstream portion of the guide flow path 12a.
  • the plurality of openings formed in the nozzle portion 17 will be described later.
  • a plurality of die heaters 18 (6 in the example shown in FIG. 13) are provided in the left-right direction to heat the filament discharge portion 12.
  • the heating temperature of the die heater 18 is controlled, for example, based on the detection signal of the temperature sensor provided in the filament discharge unit 12.
  • Thermoplastic resins that can be used as materials for filament three-dimensional conjugates include, for example, polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, polyamide resins such as nylon 66, polyvinyl chloride resins and polystyrene.
  • thermoplastic elastomers such as styrene-based elastomers, vinyl chloride-based elastomers, olefin-based elastomers, urethane-based elastomers, polyester-based elastomers, nitrile-based elastomers, polyamide-based elastomers, and fluorine-based elastomers can be used.
  • thermoplastic resin supplied from the material charging section 13 is heated and melted in the cylinder 11a and extruded by, for example, a screw 14, so that the molten thermoplastic resin is used as a molten thermoplastic resin from the cylinder discharge port 11b to the filament discharge section 12 guide flow path 12a. Is supplied to. After that, the molten filament group MF composed of the plurality of molten filaments is discharged so as to translate downward from each of the plurality of openings of the nozzle portion 17.
  • the fusion splicing forming portion 20 includes a cooling water tank 23, a pair of conveyors 24, a plurality of transport rollers 25a to 25h, and a receiving portion 300.
  • the receiving portion 300 includes a first receiving plate 31 and a second receiving plate 32.
  • the first receiving plate 31 (front receiving plate 30) and the second receiving plate 32 (rear receiving plate 30) are provided as a pair of front and rear receiving plates 30, and the thickness and width of the filament three-dimensional coupled body 3DF can be adjusted. Plays a regulatory role.
  • the cooling water tank 23 is a water tank for storing the cooling water W. Inside the cooling water tank 23, a pair of conveyors 24 and a plurality of transfer rollers 25a to 25h are arranged. The pair of conveyors 24a, 24b and the plurality of conveyors 25a to 25h are driven by a drive motor (not shown).
  • FIG. 14 is a schematic perspective view of the receiving portion 300.
  • the receiving portion 300 includes a first receiving plate 31, a second receiving plate 32, a third receiving plate 33, a first side plate 34, a fourth receiving plate 35, and a second side plate 36.
  • the first receiving plate 31 is a metal plate having a flat plate-shaped inclined portion 31A that is inclined downward toward the rear and a bent portion including a flat plate-shaped vertical portion 31B extending downward in the vertical direction from the lower end of the inclined surface 31A. be.
  • the second receiving plate 32 is a metal plate having a flat plate-shaped inclined portion 32A that is inclined downward toward the front and a bent portion including a flat plate-shaped vertical portion 32B extending downward in the vertical direction from the lower end of the inclined portion 32A. be.
  • These vertical portions 31B and 32B are parallel to each other and face each other in the front-rear direction.
  • the third receiving plate 33 is a metal plate fixed to the left ends of the inclined portions 31A and 32A by welding or the like, and has a flat plate shape that is inclined downward toward the right.
  • the first side surface plate 34 is a metal plate fixed to the left ends of the vertical portions 31B and 32B and the lower ends of the third receiving plate 33 by welding or the like.
  • the fourth receiving plate 35 is a metal plate fixed to the right ends of the inclined portions 31A and 32A by welding or the like, and has a flat plate shape that is inclined downward toward the left.
  • the second side surface plate 36 is a metal plate fixed to the right ends of the vertical portions 31B and 32B and the lower ends of the fourth receiving plate 35 by welding or the like.
  • a rectangular parallelepiped tubular portion 300A is formed by the vertical portions 31B and 32B, the first side plate 34, and the second side plate 36.
  • the front-rear and left-right size inside the cylinder portion 300A is set according to the up-down and left-right size of the cushion body to be manufactured.
  • FIG. 15 is a bottom view of the nozzle portion 17 as viewed from below.
  • a plurality of openings 171 for discharging the molten filament group are formed in the nozzle portion 17.
  • the openings 171 are arranged in the left-right direction to form one row, and the one row is arranged in the front-rear direction, forming a staggered arrangement as a whole.
  • the cross-sectional shape of the opening 171 is, for example, a circle with an inner diameter of 1 mm.
  • the number of openings 171 and the arrangement form shown in FIG. 15 are merely examples.
  • the front-rear and left-right directions of the region where the opening 171 is arranged in the nozzle portion 17 are set to be substantially equal to or slightly larger than the front-back and left-right directions sizes of the tubular portion 300A described above.
  • the molten filament group MF discharged from the nozzle portion 17 advances to the cooling water tank 23 via the receiving portion 300 (inside the tubular portion 300A), bends due to the buoyancy action of the cooling water W in the cooling water tank 23, and forms a random loop.
  • Random loops are three-dimensionally entangled with adjacent random loops in a molten state, and the contact points are fused and bonded to form a three-dimensional filament bond.
  • the combined body is discharged to the outside of the cooling water tank 23 as the filament three-dimensional bonded body 3DF by being conveyed while being cooled by the cooling water W in the cooling water tank 23 by the conveyor 24 and the plurality of transport rollers 25a to 25h.
  • the manufacturing apparatus 1 cools the molten filament group MF discharged from the plurality of openings 171 to fuse-bond them, and transports the fused-bonded conjugate (here, here). It is designed to pull in to (downward).
  • the filament three-dimensional coupled body 3DF formed continuously in the transport direction in this way is cut at predetermined lengths and can be applied as the cushion body X described above.
  • the operating speeds (rotational speeds) of the conveyor 24 and the plurality of conveyors 25a to 25h are controlled by a controller (not shown), and the operating speeds can be appropriately changed.
  • the width direction of the filament three-dimensional conjugate 3DF corresponds to the width direction of the cushion body X.
  • the thickness direction of the filament three-dimensional coupled body 3DF corresponds to the height direction of the cushion body X.
  • the transport direction in the fusion bond forming portion 20 of the filament three-dimensional bond 3DF corresponds to the depth direction of the cushion body X.
  • the operating speeds of the conveyor 24 and the plurality of transport rollers 25a to 25h are controlled when the filament three-dimensional coupled body 3DF is manufactured by the manufacturing apparatus 1. It may be changed to change the speed of pulling in the above-mentioned conjugate in the transport direction.
  • the faster the operation speed the faster the molten filament group MF immediately after advancing to the cooling water tank 23 is drawn downward, and the number of filaments per unit volume of the filament three-dimensional conjugate 3DF corresponding to this portion is increased accordingly. It becomes less and the repulsive force becomes lower.
  • the region Sd of the cushion body X can be formed by relatively slowing the operating speed of the conveyor 24 and the plurality of transport rollers 25a to 25h. By making the operation relatively fast, the portion of the region Sa of the cushion body X can be formed. By alternately switching the operation speed, the portion of the region Sd of the cushion body X and the portion of the region Sa of the cushion body X can be alternately formed.
  • the number of openings 171 formed in the nozzle portion 17 is adjusted when the filament three-dimensional coupled body 3DF is manufactured by the manufacturing apparatus 1. You just have to do it. The smaller the number of openings 171 in a predetermined region of the nozzle portion 17 (that is, the degree of density of the openings 171 is reduced), the smaller the number of filaments per unit volume of the filament three-dimensional conjugate 3DF corresponding to the region is. The repulsive force becomes low.
  • the filament three-dimensional conjugate 3DF corresponding to the region is a filament per unit volume.
  • the number increases and the repulsive force increases.
  • the diameter of the opening 171 may be adjusted. In this case, the larger the diameter of the opening 171 is, the larger the filament diameter is and the higher the repulsive force is.
  • the opening 171 of the nozzle portion 17 when the opening 171 of the nozzle portion 17 is provided as shown in FIG. 16, in the left-right central region of the cushion body X (the region corresponding to the region A1 where the opening 171 is small), the left-right end regions (openings 171).
  • the repulsive force is smaller than that of the region (region corresponding to the region A2) in which there are many.
  • the repulsive force when the opening 171 of the nozzle portion 17 is provided as shown in FIG. 17, the repulsive force is the lowest in the left-right central region of the cushion body X (the region corresponding to the region B1 where the opening 171 is the smallest), and the left and right sides are the lowest.
  • the repulsive force is highest in the region at both ends in the direction (the region corresponding to the region B3 having the largest opening 171), and the repulsive force in the region between them (the region corresponding to the region B2) is the repulsive force in the central region in the left-right direction.
  • the repulsive force is lower than the repulsive force in both ends in the left-right direction.
  • the cushion body X in which the repulsive force is changed in both the front-rear and left-right directions such as the cushion body 101 shown in FIG. 1 and the upper cushion portion 121 shown in FIG. 5, the nozzle portion 17 shown in FIG. , And change the operating speed of the conveyor 24 and the plurality of transport rollers 25a to 25h.
  • a portion of the cushion body X in which the regions Sd, Sc, Sb, Sc, and Sd are arranged in order is formed on the left and right sides.
  • the cushion body X By making the operation relatively fast, it is possible to form a portion of the cushion body X in which the Sc, Sb, Sa, Sb, and Sc regions are arranged in order on the left and right sides. By alternately switching the operating speed, the cushion body X portion in which the Sd, Sc, Sb, Sc, and Sd regions are arranged in order on the left and right, and the Sc, Sb, Sa, Sb, and Sc regions on the left and right.
  • the portions of the cushion body X in which are arranged in order can be formed alternately.
  • a normal cushion body (without a cavity) is first formed, and the cushion body is used.
  • a method of separately performing a process of providing a cavity for example, a process of cutting out a portion to be made a cavity.
  • each opening 171 at a position corresponding to the cavity in the nozzle portion 17 is closed, and the filament is not discharged from these openings 171.
  • the cavity may be provided in this way.
  • FIG. 18 illustrates the state around the receiving portion 300 when the filament is prevented from being discharged from each opening 171 at the position corresponding to the cavity (the position shown by the dotted line frame in this figure). After forming the cushion body having the cavity as shown in FIG. 18, further necessary processing may be performed in order to adjust the shape and size of the cavity to a desired state.
  • the cushion bodies 101 to 103 of each of the above-described embodiments are cushion bodies for pillows formed to support the head of the user in the sleeping posture, and the repulsive force in the regions on both ends in the width direction is applied. It is higher than the repulsive force in the central region. Therefore, according to the cushion bodies 101 to 103, the head is moderately submerged due to its cushioning property, but the repulsive force at the end in the width direction is relatively high, so that the head is in the width direction. It is possible to suppress unintentional movement from the central part to the end part as much as possible, and to stabilize the head position in the central part in the width direction.
  • the repulsive force in the regions on both ends in the width direction is higher than the repulsive force in the region in the central portion, so that the head position is more stable in the central portion in the width direction. It is possible to make it.
  • the repulsive force in the region on both ends in the depth direction is higher than the repulsive force in the region in the central portion. Therefore, according to the cushion bodies 101 to 103, it is possible to appropriately support the area around the cervical spine of the user with a portion having a relatively high repulsive force.
  • the cushion bodies 101 to 103 of each embodiment since the repulsive force in the region on both ends in the depth direction is higher than the repulsive force in the region in the central portion, the cushion bodies 101 to 103 are arranged in the opposite directions. Even so, it is possible to properly support the area around the user's cervical spine.
  • the molten filament group MF is discharged downward from the plurality of openings 171 of the nozzle portion 17, and the discharged molten filament group MF is cooled. It includes a fusion bond forming process of performing fusion bonding and pulling the fusion-bonded bond downward.
  • the diameter dimension or the degree of density of the opening 171 is changed for each different region of the nozzle portion 17, and the pulling speed is changed for each predetermined time interval to change the cushion body.
  • the repulsive force is changed for each different area. This makes it possible to easily manufacture a cushion body in which the repulsive force changes in both the width direction and the depth direction.
  • the present invention can be used for pillows and the like used during sleep.

Landscapes

  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Otolaryngology (AREA)
  • Pulmonology (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
PCT/JP2021/037855 2020-11-04 2021-10-13 クッション体およびその製造方法 Ceased WO2022097435A1 (ja)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US18/035,110 US12557928B2 (en) 2020-11-04 2021-10-13 Cushion member and method for manufacturing the same
EP21888988.9A EP4241626B1 (en) 2020-11-04 2021-10-13 Cushioning body and method for manufacturing same
JP2022560689A JPWO2022097435A1 (https=) 2020-11-04 2021-10-13

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2020-184358 2020-11-04
JP2020184358 2020-11-04

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WO2022097435A1 true WO2022097435A1 (ja) 2022-05-12

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US (1) US12557928B2 (https=)
EP (1) EP4241626B1 (https=)
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DK202370425A1 (en) * 2022-12-29 2024-08-05 Lear Corp Cushion assembly
JP2024141400A (ja) * 2023-03-29 2024-10-10 株式会社ルービックＪｐ 枕
JP7587905B1 (ja) * 2024-04-08 2024-11-21 株式会社エコ・ワールド 枕
JP2025009763A (ja) * 2023-07-06 2025-01-20 禾▲豊▼（青▲島▼）家紡有限公司 ファイバー詰め物及びその製造装置
US12269384B2 (en) 2021-03-31 2025-04-08 Lear Corporation Seat support
US12286044B2 (en) 2023-05-12 2025-04-29 Lear Corporation Method and apparatus for producing a vehicle interior component
US12286045B2 (en) 2021-12-02 2025-04-29 Lear Corporation Vehicle seating system and method for producing same
US12319183B2 (en) 2021-03-31 2025-06-03 Lear Corporation Seat support
US12325168B2 (en) 2021-12-20 2025-06-10 Lear Corporation System and method of making a mesh cushion
US12325624B2 (en) 2023-03-06 2025-06-10 Lear Corporation Seat assembly, cushion, and tool and method of forming
US12384094B2 (en) 2022-03-08 2025-08-12 Lear Corporation Method for producing a vehicle interior component
US12454111B2 (en) 2022-05-11 2025-10-28 Lear Corporation Tool to manufacture a cushion
US12479143B2 (en) 2021-12-20 2025-11-25 Lear Corporation System and method of making a mesh cushion
US12509343B2 (en) 2023-02-28 2025-12-30 Lear Corporation Automated trench manufacturing and assembly for attaching trim covers to a cushion assembly
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Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12319183B2 (en) 2021-03-31 2025-06-03 Lear Corporation Seat support
US12269384B2 (en) 2021-03-31 2025-04-08 Lear Corporation Seat support
US12286045B2 (en) 2021-12-02 2025-04-29 Lear Corporation Vehicle seating system and method for producing same
US12479143B2 (en) 2021-12-20 2025-11-25 Lear Corporation System and method of making a mesh cushion
US12325168B2 (en) 2021-12-20 2025-06-10 Lear Corporation System and method of making a mesh cushion
US12384094B2 (en) 2022-03-08 2025-08-12 Lear Corporation Method for producing a vehicle interior component
US12454111B2 (en) 2022-05-11 2025-10-28 Lear Corporation Tool to manufacture a cushion
DK202370425A1 (en) * 2022-12-29 2024-08-05 Lear Corp Cushion assembly
US12509343B2 (en) 2023-02-28 2025-12-30 Lear Corporation Automated trench manufacturing and assembly for attaching trim covers to a cushion assembly
US12325624B2 (en) 2023-03-06 2025-06-10 Lear Corporation Seat assembly, cushion, and tool and method of forming
JP2024141400A (ja) * 2023-03-29 2024-10-10 株式会社ルービックＪｐ 枕
US12286044B2 (en) 2023-05-12 2025-04-29 Lear Corporation Method and apparatus for producing a vehicle interior component
JP7688180B2 (ja) 2023-07-06 2025-06-03 禾▲豊▼（青▲島▼）家紡有限公司 ファイバー詰め物及びその製造装置
JP2025009763A (ja) * 2023-07-06 2025-01-20 禾▲豊▼（青▲島▼）家紡有限公司 ファイバー詰め物及びその製造装置
WO2025215702A1 (ja) * 2024-04-08 2025-10-16 株式会社エコ・ワールド 枕
JP7587905B1 (ja) * 2024-04-08 2024-11-21 株式会社エコ・ワールド 枕
WO2026058577A1 (ja) * 2024-09-13 2026-03-19 株式会社エアウィーヴ 枕

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EP4241626B1 (en) 2025-12-17
US20240008664A1 (en) 2024-01-11
EP4241626A1 (en) 2023-09-13
US12557928B2 (en) 2026-02-24
JPWO2022097435A1 (https=) 2022-05-12
EP4241626A4 (en) 2024-10-30

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