Three-dimensional network structure

Abstract

The three-dimensional network structure (1) is a structure in which a plurality of wire-shaped molten resins are wound together and partially thermally welded, a hard region (10) having a higher bulk density than the surrounding is provided in a portion of the thickness, and the position of the hard region (10) in the thickness direction changes midway. As a result, it is possible to impart a prescribed hardness to any portion of the three-dimensional network structure (1) without increasing the weight too much. In addition, the comfort of the three-dimensional network structure (1) can be improved.

Description

Technical Field

[0001] This invention relates to a three-dimensional mesh structure formed by intertwining and partially thermally fusing multiple linear molten resin strands. Background Technology

[0002] Mattresses or pillows that use a mesh structure formed by three-dimensional weaving of resin are known.

[0003] Here, Patent Document 1 discloses a mattress made of a woven resin mesh structure. The waist and hip area has a first layer and a second layer, the back area has a first layer and a second layer, and the leg area has a first layer and a second layer. The packing density of the first layer of the back area is set to be less than that of the first layer of the waist and hip area, the packing density of the first layer of the leg area is set to be less than that of the first layer of the waist and hip area, the packing density of the second layer of the waist and hip area is set to be greater than that of the first layer of the waist and hip area, the packing density of the second layer of the back area is set to be greater than that of the first layer of the back area, and the packing density of the second layer of the leg area is set to be greater than that of the first layer of the leg area.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2017-86321 Summary of the Invention The technical problem that the invention aims to solve According to the invention described in Patent Document 1, a mattress pad can be provided that achieves optimal resilience and texture in the waist, hip, back, and leg areas, and easily achieves a balance between body pressure distribution and sleep posture maintenance. However, due to the change in the packing density of each layer, the areas with higher packing density increase, resulting in increased weight.

[0005] Therefore, the object of the present invention is to provide a three-dimensional mesh structure that can achieve a specified rigidity in any part without increasing the weight, and can improve comfort.

[0006] Solution to the above technical problems The three-dimensional mesh structure 1 of the present invention described in Scheme 1 is characterized in that it is a structure formed by multiple linear molten resin strands intertwined and partially thermally fused together, and a portion of its thickness is provided with hard regions 10, 20, and 30 with a higher packing density than the surrounding area, and the positions of the hard regions 10, 20, and 30 in the thickness direction change midway.

[0007] The present invention described in Scheme 2 is characterized in that, in the three-dimensional mesh structure 1 described in Scheme 1, the hard regions 10 and 30 are waveforms.

[0008] The present invention described in Scheme 3 is characterized in that, in the three-dimensional mesh structure 1 described in Scheme 1, the portion connecting the portion located at one position in the thickness direction to the portion located at the other position in the hard regions 10, 20, and 30 is inclined.

[0009] The present invention described in Scheme 4 is characterized in that the three-dimensional mesh structure 1 described in Scheme 1 is a mattress or quilt, and the position of the hard region 30 located in the upper surface 1A where the user 2's shoulder 2B is placed is further down the lower surface 1B than the position of the hard region 30 located in the upper surface 1A where the user 2's head 2A is placed.

[0010] The present invention described in Scheme 5 is characterized in that, in the three-dimensional mesh structure 1 described in Scheme 4, the hard region 30 located in the part on the upper surface 1A where the user 2's ankle 2F is placed is positioned in the thickness direction further to the lower surface 1B than the hard region 30 located in the part on the upper surface 1A where the user 2's calf 2E is placed.

[0011] The present invention described in Scheme 6 is characterized in that, in the three-dimensional mesh structure 1 described in Scheme 5, the hard region 30 located in the part of the upper surface 1A where the buttocks 2D of the user 2 are placed is wavy.

[0012] Invention Effects According to the present invention, for a three-dimensional mesh structure, compared with the case where no hard areas are provided, it is possible to make any part have a specified hardness without increasing the weight, and to improve comfort. Attached Figure Description

[0013] Figure 1 This is a diagram illustrating a three-dimensional mesh structure according to a first embodiment of the present invention.

[0014] Figure 2 This is a diagram showing a three-dimensional mesh structure according to a second embodiment.

[0015] Figure 3 This is a diagram showing a three-dimensional mesh structure according to a third embodiment.

[0016] Figure 4 This is a diagram showing an example of a manufacturing apparatus for its three-dimensional mesh structure.

[0017] Figure 5 This is a diagram showing an example of a hole on the bottom surface of its resin tank. Detailed Implementation

[0018] The three-dimensional mesh structure of the first embodiment of the present invention is a structure formed by intertwining and partially thermally fusing multiple linear molten resin strands. A hard region with a higher packing density than the surrounding area is provided in a portion of the thickness, and the position of the hard region in the thickness direction changes midway.

[0019] According to this embodiment, by providing a hard region along a portion of the thickness, a predetermined hardness can be achieved in any part of the three-dimensional mesh structure without significantly increasing weight. Furthermore, by changing the position of the hard region along the thickness direction midway, the degree of depression and tactile feel of the three-dimensional mesh structure can be made more suitable, thereby improving comfort.

[0020] The second embodiment of the present invention is that, in the three-dimensional mesh structure of the first embodiment, the hard regions are wavy.

[0021] According to this embodiment, different parts such as tactile sensation can be alternately formed along the length direction of the three-dimensional mesh structure, or the strength of the three-dimensional mesh structure can be further increased.

[0022] The third embodiment of the present invention is that, in the three-dimensional mesh structure of the first embodiment, the portion connecting the portion located at one position in the thickness direction to the portion located at the other position in the hard region is inclined.

[0023] According to this embodiment, the degree of sinking and the change in tactile sensation of the three-dimensional mesh structure can be made smoother.

[0024] In the fourth embodiment of the present invention, the three-dimensional mesh structure of the first embodiment is a mattress or quilt, and the position in the thickness direction of the hard area of ​​the upper surface where the user's shoulders are placed is further down the surface than the position in the thickness direction of the hard area of ​​the upper surface where the user's head is placed.

[0025] According to this embodiment, it is possible to prevent the part corresponding to the head in the three-dimensional mesh structure from sinking excessively, while giving the part corresponding to the shoulder a tactile sensation as if it were sinking into the three-dimensional mesh structure.

[0026] The fifth embodiment of the present invention is that, in the three-dimensional mesh structure of the fourth embodiment, the position in the thickness direction of the hard region located on the upper surface where the user's ankle is placed is further down the surface than the position in the thickness direction of the hard region located on the upper surface where the user's calf is placed.

[0027] According to this embodiment, it is possible to prevent the portion of the three-dimensional mesh structure corresponding to the lower leg from sinking excessively, while giving the portion corresponding to the ankle a tactile sensation as if it were sinking into the three-dimensional mesh structure.

[0028] The sixth embodiment of the present invention is that, in the three-dimensional mesh structure of the fifth embodiment, the hard region located on the upper surface where the user's buttocks are placed is wavy.

[0029] According to this embodiment, the strength of the area corresponding to the buttocks can be improved, and the durability of the three-dimensional mesh structure can be enhanced.

[0030] [Example] The following describes the three-dimensional mesh structure according to an embodiment of the present invention.

[0031] Figure 1 This is a diagram illustrating the three-dimensional mesh structure of the first embodiment. Figure 1 (a) is a side (cut-off) photograph. Figure 1 (b) is a schematic diagram of the hard region on the side. Figure 1 (c) is the top view. Additionally, Figure 2 This is a diagram illustrating the three-dimensional mesh structure of the second embodiment. Figure 2 (a) is a side (cut-off) photograph. Figure 2 (b) is a schematic diagram of the hard region on the side. Figure 2 (c) is the top view.

[0032] The three-dimensional mesh structure 1, made of woven resin, is formed by intertwining and partially thermally fusing multiple strands of molten resin. The three-dimensional mesh structure 1 is used, for example, in mattresses, quilts, and pillows, and is typically rectangular when viewed from above.

[0033] The three-dimensional network structure 1 is formed by melting and kneading thermoplastic resins at a specified temperature, allowing the molten resin to flow down in a linear stream and then cooling it. Examples of thermoplastic resins include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polytetrafluoroethylene, and acrylonitrile-butadiene-styrene resin. These resins can be used alone or in mixtures of two or more.

[0034] The three-dimensional mesh structure 1, manufactured from thermoplastic resin, can be recycled after use and reused as a raw material for the three-dimensional mesh structure 1. Furthermore, since the three-dimensional mesh structure 1 can be cleaned with water, it is easy to keep clean.

[0035] The three-dimensional mesh structure 1 in this embodiment is a cuboid with a single-layer structure and approximately constant packing density between the upper surface 1A and the lower surface 1B, and has a specified length L, width W, and thickness (height) H.

[0036] Between the upper surface 1A and the lower surface 1B, a portion of it forms a bulk density [g / cm³]. 3The thin, plate-like hard regions 10 and 20 are larger than the surrounding ones, and the woven resin of the hard regions 10 and 20 is intertwined with the woven resin of the surrounding ones.

[0037] The longitudinal and transverse dimensions (length and width dimensions) of hard regions 10 and 20 are approximately equal to the longitudinal and transverse dimensions L×W of the three-dimensional mesh structure 1, extending from the front surface 1C to the rear surface 1D, and from the left side 1E to the right side 1F. In a cross-section parallel to the thickness direction, hard regions 10 and 20 appear as follows: Figure 1 (b) or Figure 2 The continuous linear (strip) shape is shown in (b). By setting hard regions 10, 20 in a portion of the thickness in this way, it is possible to give any part of the three-dimensional mesh structure 1 a specified hardness without increasing the weight.

[0038] In addition, in this embodiment, the three-dimensional mesh structure 1 is a single-layer structure, but it can also be configured as a multi-layer structure with multiple layers of different packing densities formed between the upper surface 1A and the lower surface 1B. Furthermore, the three-dimensional mesh structure 1 can also be configured as a segmented type, as in the third embodiment described later.

[0039] Furthermore, the hard regions 10 and 20 can also have different longitudinal and transverse dimensions than the longitudinal and transverse dimensions L×W of the three-dimensional mesh structure 1. For example, their length can be shorter than the length L of the three-dimensional mesh structure 1, and they can also be formed discontinuously in the length direction.

[0040] The hard regions 10 and 20 can be freely set at any position within a portion of the thickness of the three-dimensional mesh structure 1, and the patterns formed by the hard regions 10 and 20 can express various degrees of depression and tactile sensations.

[0041] Hard regions 10 and 20 can be formed as a straight line so that their position in the thickness direction is constant from the front surface 1C to the rear surface 1D, but in this embodiment, their position in the thickness direction changes midway. For example, Figure 1 The hard region 10 is formed as a waveform with alternating peaks and troughs, and its position changes periodically in the thickness direction. The peak of the waveform is located above the center of the thickness direction of the three-dimensional mesh structure 1, and the trough is located below the center of the thickness direction. On the other hand, Figure 2 The hard region 20 is formed such that it extends from the front surface 1C to near the center in the length direction, is located below the center in the thickness direction and has a constant height, and extends from the rear surface 1D to near the center, is located above the center in the thickness direction and has a constant height, thereby causing the position in the thickness direction to change back and forth.

[0042] Since the upper and lower parts of the hard regions 10 and 20 in the three-dimensional mesh structure 1 have different degrees of sinking and tactile sensation when placed on the user's head or body, by changing the position of the hard regions 10 and 20 in the thickness direction according to the body parts, the degree of sinking and tactile sensation of each part of the three-dimensional mesh structure 1 can be made more suitable, thereby helping to improve comfort.

[0043] Furthermore, in the hard regions 10 and 20, the portion connecting the part located at one position (lower side) to the part located at the other position (upper side) is inclined. By forming the boundary portion in the hard regions 10 and 20 where the position changes in the thickness direction as inclined, the degree of depression and the change in tactile sensation of each part of the three-dimensional mesh structure 1 can be made smoother.

[0044] In addition, Figure 1 In the waveform hard region 10 shown, the tilt angle of the portion connecting the peaks and troughs exceeds 0 degrees and is less than 50 degrees. By setting the hard region 10 as a gently tilted waveform in this way, different parts such as tactile sensations can be alternately arranged in the length direction of the three-dimensional mesh structure 1.

[0045] Next, the three-dimensional mesh structure according to the third embodiment of the present invention will be described. Furthermore, the same reference numerals are used for the same parts as in the above embodiments, and descriptions are omitted.

[0046] Figure 3 This is a diagram illustrating the three-dimensional mesh structure of the third embodiment. Figure 3 (a) is a schematic diagram showing the usage status from the side. Figure 3 (b) is a schematic diagram of the hard region on the side.

[0047] The three-dimensional mesh structure 1 in this embodiment is used as a mattress or quilt. Furthermore, the mattress or quilt in this embodiment is a segmented type where three three-dimensional mesh structures 1 are arranged side-by-side along the length of the cover, but it can also be a one-piece molded type, similar to the first and second embodiments.

[0048] Similar to the first and second embodiments, the three-dimensional mesh structure 1 of this embodiment has a thin plate-shaped hard region 30 with a higher packing density than the surrounding area formed in a portion of the thickness between the upper surface 1A and the lower surface 1B. The longitudinal and transverse dimensions (length and width dimensions) of the hard region 30 are approximately equal to the longitudinal and transverse dimensions L×W of the three-dimensional mesh structure 1.

[0049] In the hard region 30, the portion corresponding to the head 2A of the lying user 2 is located above the center in the thickness direction and has a constant height, while the portion corresponding to the shoulder 2B is located below the center in the thickness direction and has a constant height. The portion in between is inclined. By forming the portion of the hard region 30 corresponding to the area on the upper surface 1A where the user 2's shoulder 2B is placed, which is located on the lower surface 1B side, it is possible to prevent the portion corresponding to the head 2A in the three-dimensional mesh structure 1 from sinking excessively, while giving the portion corresponding to the shoulder 2B a tactile sensation as if it were sinking into the three-dimensional mesh structure 1.

[0050] Furthermore, in the hard region 30, the portion corresponding to the lower leg 2E of the user 2 lying down is located above the center in the thickness direction and its position in the thickness direction is constant, while the portion corresponding to the ankle 2F is located below the center in the thickness direction and its position in the thickness direction is constant, and the portion between the two is inclined. By forming the portion of the hard region 30 corresponding to the part on the upper surface 1A where the user 2's ankle 2F is placed is further below the lower surface 1B than the portion corresponding to the part on the upper surface 1A where the lower leg 2E is placed, it is possible to prevent the portion corresponding to the lower leg 2E in the three-dimensional mesh structure 1 from sinking excessively, while giving the portion corresponding to the ankle 2F a tactile sensation as if it were sinking into the three-dimensional mesh structure 1.

[0051] Furthermore, in the hard region 30, the portion corresponding to the waist 2C and buttocks 2D of the lying user 2 is formed as a waveform. The peak of the waveform is located above the center in the thickness direction, and the trough is located below the center in the thickness direction. The wavelength of this waveform portion is shorter than the wavelength of the waveform portion in the first embodiment, and the tilt angle connecting the peak and the trough is 50 degrees or more and less than 90 degrees.

[0052] Since the parts with steeply inclined waveforms of hard regions 30 have higher strength than the parts with straight hard regions 30, the durability of the three-dimensional mesh structure 1 can be improved by setting the hard regions 30 with steeply inclined waveforms of hard regions 30 corresponding to the waist 2C and hip 2D which are prone to sinking.

[0053] Figure 4 This is a diagram illustrating an example of a manufacturing apparatus for the three-dimensional mesh structure of the present invention. Figure 5 This is a diagram showing an example of a hole on the bottom surface of a resin tank.

[0054] The manufacturing apparatus of this embodiment includes: an extruder 110 for melting and kneading thermoplastic resin at a specified temperature to form molten resin, and for extruding the molten resin at a specified extrusion speed; a resin tank 130 for receiving the molten resin extruded from the extruder 110 and for causing the molten resin to flow down in a linear fashion from a plurality of holes (nozzles) on the bottom surface 131; a cooling water tank 140 for storing cooling water; and a traction machine 150 for drawing the woven resin 121 formed by cooling the linear molten resin 120 flowing down from the resin tank 130 with cooling water downwards. The traction machine 150 is provided with a plurality of traction rollers 151 facing each other and is disposed within the cooling water tank 140. Furthermore, a guide 170 is provided between the resin tank 130 and the traction machine 150.

[0055] Linear molten resin 120 is formed by flowing down through holes in the bottom surface 131 of the resin tank 130. The braided resin 121, formed by cooling the linear molten resin 120 with cooling water, is drawn towards the bottom plate side of the cooling water tank 140 by a traction machine 150. After passing through the traction machine 150, it is simultaneously cooled in the cooling water and lifted obliquely upwards by multiple conveying rollers 160, which act as lifting components within the cooling water tank 140, and conveyed outside the cooling water tank 140. Then, after cooling, it is cut to a predetermined size, thereby forming a three-dimensional mesh structure 1. Furthermore, the direction orthogonal to the extrusion direction is the length direction of the three-dimensional mesh structure 1, and the direction parallel to the extrusion direction is the width direction of the three-dimensional mesh structure 1. The thickness of the three-dimensional mesh structure 1 is approximately equal to the spacing of the traction rollers 151. In addition, by narrowing the width of the bundle of linear molten resin 120 as it passes through the guide 170, the upper surface 1A and lower surface 1B of the three-dimensional mesh structure 1 are smoothly formed.

[0056] The hard regions 10, 20, and 30 in the three-dimensional mesh structure 1, for example, are formed by means of... Figure 5 The holes on the bottom surface 131 of the resin pool 130 are locally increased along a prescribed line, and can be freely formed at any position. Additionally, in Figure 5 In the diagram, holes added to form hard areas are shown in black. The holes added to form hard areas can be set to the same size as the original holes (white holes in the diagram), or they can be set to a different size.

[0057] Explanation of reference numerals in the attached figures 1. Three-dimensional mesh structure 1A Upper Surface 1B Lower surface 1C front surface 1D back surface 1E Left side 1F Right Side 2 users 2A Head 2B Shoulder 2C Waist 2D buttocks 2E calf 2F Ankle Hard areas: 10, 20, 30.

Claims

1. A three-dimensional mesh structure, characterized in that, It is a structure made of multiple linear molten resin strands intertwined and partially thermally fused together. A hard region with a higher packing density than the surrounding area is set in a portion of the thickness. The position of the hard region in the thickness direction changes midway.

2. The three-dimensional mesh structure as described in claim 1, characterized in that, The hard region is wavy.

3. The three-dimensional mesh structure as described in claim 1, characterized in that, In the hard region, the portion connecting the portion located at one position in the thickness direction to the portion located at the other position is inclined.

4. The three-dimensional mesh structure as described in claim 1, characterized in that, The three-dimensional mesh structure is a mattress or quilt, and the hard area of ​​the upper surface where the user's shoulders rest is located in the thickness direction is further down the surface than the hard area of ​​the upper surface where the user's head rests.

5. The three-dimensional mesh structure as described in claim 4, characterized in that, The hard region located on the upper surface where the user's ankle rests is positioned in the thickness direction is further down the surface than the hard region located on the upper surface where the user's calf rests.

6. The three-dimensional mesh structure as described in claim 5, characterized in that, The hard area located on the upper surface where the user's buttocks rest is wavy.

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