Antibacterial and antivirus mat product

Abstract

To provide a mat product that can be sanitarily used for a long time without using a cover, a sheet, or the like.SOLUTION: A mat product includes: a mat body formed of a foamable material; and an antibacterial and antivirus coating layer formed of a plastic film and attached to all faces of the mat body. At least one face of the antibacterial and antivirus coating layer is formed with minute irregularities or the mat body has a rectangular parallelepiped shape, and a structure having irregularities for body pressure dispersion is formed in one of side faces having the largest area among the faces of the rectangular parallelepiped shape.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a mat product that can be used hygienically without the use of a cover or sheet, and more particularly, to a mat product having an antibacterial and antiviral coating layer on its surface. [Background technology]

[0002] Mattresses, pillows, cushions, cushions, and other mat products are often used with sheets and covers. Such products can be kept highly hygienic by washing the sheets regularly. In recent years, mat products are also required to have antibacterial and antiviral properties, and sheets with antibacterial and antiviral properties are being used.

[0003] In this situation, a technology has been proposed for washable mattresses to enable more hygienic use (Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2023-015485 Summary of the Invention [Problem to be solved by the invention]

[0005] In nursing and medical facilities, a series of tasks for changing sheets, such as moving patients, removing sheets, washing, and bed making, must be performed for many patients, which is very hard work. Therefore, in such facilities, there is a growing demand for mat products that can be used hygienically without using sheets.

[0006] The present invention has been made in consideration of the above, and has an object to provide an antibacterial and antiviral mat product that can be used hygienically without the use of a sheet or cover. [Means for solving the problem]

[0007] The first invention for solving the above problems is a mat product comprising a mat body made of a foamable material and an antibacterial and antiviral coating layer made of plastic provided directly on all surfaces of the mat body, at least one surface of the antibacterial and antiviral coating layer having fine irregularities formed thereon.

[0008] The second invention for solving the above problems is a mat product comprising a mat body made of a foamable material and an antibacterial and antiviral plastic coating layer provided directly on all surfaces of the mat body, the mat body being approximately rectangular and having an uneven structure for dispersing body pressure formed on one of its sides having the largest area.

[0009] In the first and second aspects of the present invention, an antibacterial and antiviral plastic coating layer is provided directly on all surfaces of the mat body made of a foamable material, so that the surface of the mat product is not contaminated by bacteria or viruses and can be used hygienically.

[0010] In addition, the plastic antibacterial and antiviral coating layer prevents stains from sweat, saliva, vomit, blood, etc. from penetrating into the mat body. In addition, because the coating layer is provided directly on the surface of the mat body, there are no gaps in the coating layer itself that allow moisture to penetrate. This means that the mat product can be easily kept clean by simple processing such as wiping.

[0011] Furthermore, the surface of the mat product (the antibacterial and antiviral coating layer) can be directly washed using high-pressure water or steam, making it even more hygienic and clean to use.

[0012] In addition, since the mat body is made of a foaming material, it has a suitable elasticity and is comfortable to use. In addition, the foaming material has small voids on the surface, so it is easy to directly provide a coating layer on the surface of the mat body.

[0013] Furthermore, in the first invention, at least one surface has fine irregularities formed thereon, and by using this surface as the side that comes into contact with the human body, breathability is ensured between the human body and the mat product, and no discomfort is caused during use.

[0014] Here, the surface that the human body touches means the surface of the mat product that is expected to be touched by the human body in normal use. For example, if the mat product is a cushion or a zabuton, all of the surfaces are surfaces that the human body touches. Also, in the case of a rectangular pillow, the four sides that are expected to come into contact with the head, hair, and neck correspond to the surfaces that the human body touches, while the two sides on both sides in the width direction do not correspond to the surfaces that the human body touches.

[0015] In addition, in the case of a rectangular parallelepiped mattress, one of the sides with the largest area corresponds to the side that the human body touches, and the other five sides do not correspond to the sides that the human body touches. Of course, fine irregularities may be formed on the surfaces other than the surface that the human body touches. In the case of a product such as a mattress where only one side comes into contact with the human body, the surface that comes into contact with the floor or bed surface may be configured with an anti-slip treatment.

[0016] In the first invention, the exterior of the mat body may be entirely made up of flat surfaces, entirely made up of curved surfaces, or a combination of flat and curved surfaces.

[0017] In the second invention, the mat body is substantially rectangular, and one of its sides with the largest surface area is formed with an uneven structure for dispersing body pressure. By using the mat body with this uneven structure on the upper side (the side on which a person sits), the body pressure of the human body is appropriately dispersed, and breathability is ensured between the mat product and the mat body, so that no discomfort is caused during use.

[0018] In the second invention, since the mat body is a substantially rectangular parallelepiped, the mat body has two or more sides with the largest area, but the uneven structure is formed on only one of the sides and not on the other sides. The shape of the uneven structure of the mat body is also reflected in the shape of the antibacterial and antiviral coating layer provided on the surface (the appearance of the mat product), forming the uneven shape.

[0019] In the first and second aspects of the present invention, the coating layer is provided directly on the mat body and there is no misalignment between the two, so the effect of the fine irregularities or the uneven structure is not reduced by the misalignment.

[0020] Here, the term "approximately rectangular parallelepiped shape" means that the shape of the foamable material, ignoring voids, is a rectangular parallelepiped or a rectangular parallelepiped with at least one corner chamfered or rounded.

[0021] In the present invention, the term "antibacterial and antiviral properties" means antibacterial and antiviral properties according to the standards of the Society of International Studies on Antibacterial Articles (SIAA), and preferably further antifungal properties according to the SIAA standards.

[0022] Furthermore, the method for imparting antibacterial and antiviral properties to plastics is not particularly limited, and for example, commercially available plastic films or coating materials that have been treated with antibacterial and antiviral properties can be used.

[0023] Furthermore, it is essential that the covering layer made of plastic has waterproof properties that prevent moisture from penetrating into the interior, and it is more preferable that it has small wear during long-term use, durability against chemicals such as wiping with alcohol or a chlorine-based disinfectant, and durability against sterilization treatment at high temperatures.

[0024] The covering layer may be formed by attaching a plastic film to the surface of the mat body by adhesive or heat welding, or may be formed as a plastic coating on the surface of the mat body. When an adhesive is used, it is preferable to attach a plastic film on which an adhesive layer is already formed to the surface of the mat body.

[0025] When using plastic films, one film may be configured to cover multiple surfaces of the mat body, or one film may be configured to cover one surface of the mat body. When using multiple films, care should be taken to prevent moisture from penetrating through the joints. There is no particular limit to the method for this, but the films may be laminated by overlapping parts, or gaps may be filled with caulking or a coating.

[0026] The mat body may have both a concave-convex structure and a fine concave-convex structure on the antibacterial and antiviral coating layer. In this case, the concave-convex structure and the fine concave-convex structure may be formed on different surfaces, but it is more preferable that the fine concave-convex structure is formed on the surface of the antibacterial and antiviral coating layer formed on the surface of the mat body on which the concave-convex structure is formed. The mat body may also have fine concave-convex structures on other surfaces.

[0027] The shape of the fine irregularities is not particularly limited. For example, a randomly roughened surface, a regularly roughened surface, or a combination of these may be used. The shapes of the protrusions and recesses are also not particularly limited, and may be linear such as straight lines or curves, dots, or amorphous fields.

[0028] The method of forming the fine irregularities is not particularly limited. For example, a method of forming a plastic coating film on the surface of the mat body having irregularities formed on the surface by digging grooves or holes or sandblasting, a method of attaching a plastic film having increased plasticity by heating to the surface of the mat body having irregularities, a method of attaching a plastic film having fine irregularities already formed on the surface of the mat body, etc. can be adopted. In addition, it is preferable to adopt a method in which the mat body made of a foaming material is stretched by pulling and the plastic film is not stretched and is then stuck together, and the plastic film is deflected by the contraction of the mat body to form the irregularities, since this method can easily form the irregularities. The pulling in this case may be in one direction or two directions, but one direction is preferable because it is easier to process. In addition, the pulling direction is preferably parallel to the longitudinal direction of the mat product.

[0029] The amount of tension is preferably 2 to 10%, more preferably 3 to 8%, and even more preferably 4 to 6%, calculated as an area. When the tension direction is unidirectional, wrinkle-like irregularities are formed substantially perpendicular to the tension direction, and when the tension direction is bidirectional, irregularities are formed in random directions.

[0030] The surface on which the fine irregularities are formed in this way has a ratio of actual area to apparent area (actual area / apparent area) of 1.02 to 1.10. The foamable material acts to absorb the deflection, resulting in wrinkles that are convex on the mat body side (concave from the surface side).

[0031] The maximum height Sz of the surface on which the fine irregularities are formed in accordance with ISO 25178 is preferably 0.5 to 20 mm, more preferably 0.8 to 18 mm, and even more preferably 1 to 15 mm.The average height Sa in accordance with ISO 25178 is preferably 0.3 to 15 mm, more preferably 0.5 to 10 mm, and even more preferably 0.6 to 8 mm.

[0032] The uneven structure formed on the mat body may be a known uneven structure for dispersing body pressure, and the shape, size, density, arrangement, etc. of the concave and convex parts are not particularly limited. The method for forming the uneven structure may also be a known processing method, for example, a method of foaming inside a mold in which the uneven structure is formed, or a method of removing excess parts by cutting, etc. For example, a shape in which a large number of convex parts in the shape of half a spheroid are aligned, or a shape in which a large number of cone-shaped concaves and convex parts with rounded apexes are aligned, etc. may be used.

[0033] The uneven structure may be one in which concave and convex parts of the same size are regularly arranged, or one in which concave and convex parts of different sizes are randomly arranged, or one in which the size and arrangement vary depending on the location.

[0034] Furthermore, the height of one convex or concave portion of the concave-convex structure is preferably 5 to 60 mm, more preferably 12 to 55 mm, and even more preferably 20 to 50 mm.

[0035] The size of one convex or concave portion of the concave-convex structure is preferably 50 to 1000%, more preferably 70 to 800%, and even more preferably 80 to 600% of the height of the convex or concave portion. The size of a convex or concave portion means the length of the diameter of the outline surrounding the outer periphery of the convex or concave portion, and when a concave portion and a convex portion are formed, means the diameter of the convex or concave portion at the imaginary boundary surface between the concave portion and the convex portion.

[0036] The plastic material is not particularly limited as long as it has appropriate flexibility, is capable of forming a film or a coating, and is waterproof, and films made of materials such as polyethylene, polypropylene, polystyrene, and other polyolefins, polyester, polyamide, polyvinyl acetate, polyurethane, etc. Among them, it is preferable to use a material that is also excellent in abrasion resistance and chemical resistance, such as polyester, polyamide, polyurethane, etc., and polyurethane (polycarbonate-based polyurethane) using polycarbonate di(poly)ol as the polyol component is even more preferable.

[0037] The coating layer may contain, in addition to the chemical components for antibacterial and antiviral processing, one or more types of known additives, such as antioxidants, heat stabilizers, UV absorbers, flame retardants, flame retardant assistants, colorants, pigments, anti-mold agents, light resistance agents, plasticizers, tackifiers, dispersants, defoamers, curing catalysts, curing agents, leveling agents, water repellents, coupling agents, fillers, vulcanizing agents, and vulcanization accelerators, in a purposeful manner.

[0038] Moreover, if the thickness of the coating layer is too thick, the cost becomes high, and if it is too thin, it is easily worn away by abrasion, so the thickness is preferably 15 to 100 μm, more preferably 17 to 80 μm, and even more preferably 20 to 50 μm.

[0039] The mat body can be made of a known foaming material, such as foamed plastics such as polyurethane foam (urethane foam), polyethylene foam, polypropylene foam, polystyrene foam, polyethylene terephthalate foam, and natural rubber foam. Among these, the use of natural rubber foam has the advantage of providing appropriate compression resilience and being environmentally friendly because it is a plant-based product.

[0040] The thickness of the mat body is not particularly limited and may be appropriately selected according to the application. The thickness may be constant or may vary.

[0041] The expansion ratio of the expandable material (volume after expansion / volume before expansion) may be appropriately set depending on the material used and the elasticity required for the intended use.

[0042] Such a mat product can be suitably used for mattresses, pillows, cushions, seat cushions, and the seats and backs of chairs and sofas. Effect of the Invention

[0043] According to the present invention, a mat product that can be used hygienically without using a cover can be realized. [Brief description of the drawings]

[0044] [Figure 1] FIG. 1 is a diagram showing the appearance of an antibacterial and antiviral mat product according to a first embodiment. [Diagram 2] 2(a) is an enlarged view of part A in FIG. 1, and FIG. 2(b) is a cross-sectional end view taken along line BB' in FIG. 2(a). [Diagram 3] FIG. 11 is a diagram showing the appearance of an antibacterial and antiviral mat product according to a second embodiment. [Figure 4] 4 is a cross-sectional end view taken along line CC' in FIG. 3. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] (Embodiment 1) The present invention will be described below with reference to the drawings. Fig. 1 is a diagram showing the appearance of an antibacterial and antiviral mat product according to the present invention, Fig. 2(a) is an enlarged view of part A in Fig. 1, and Fig. 2(b) is an end view of a cut portion taken along line B-B' in Fig. 2(a).

[0046] As shown in Figures 1 and 2, an antibacterial and antiviral mat product 100 according to the present invention includes a mat body 10 made of expanded polyurethane (urethane foam) and an antibacterial and antiviral coating layer 20 made of plastic and formed in contact with the surface of the mat body 10. As shown in Figure 2, at least the surface of the antibacterial and antiviral coating layer that comes into contact with the human body (the upper surface in Figure 2) has a large number of fine wrinkle-like irregularities 21 formed on the mat body side.

[0047] Since the antibacterial and antiviral plastic coating layer 20 is formed directly on the surface of the mat body 10 made of a foaming material, the surface of the mat product 100 is not contaminated by viruses and can be used hygienically.

[0048] In addition, the plastic antibacterial and antiviral coating layer 20 reliably prevents stains from sweat, saliva, vomit, etc. from penetrating into the inside of the mat body 10, so hygiene can be easily maintained by simply wiping the surface, etc.

[0049] Furthermore, since the surface of the antibacterial and antiviral coating layer 20 that comes into contact with the human body is formed with fine irregularities, breathability is ensured between the human body and the mat product, and no discomfort is caused during use.

[0050] Here, the method for imparting antibacterial and antiviral properties to the plastic constituting the coating layer is not particularly limited, and commercially available plastics that have been treated with antibacterial and antiviral properties may be used.

[0051] In addition, the plastic constituting the coating layer must be waterproof to prevent water from penetrating into the interior, and it is preferable that it is resistant to small wear during long-term use and to disinfecting and cleaning chemicals such as alcohol and hypochlorous acid water.

[0052] In addition, in this embodiment, the method of forming the fine irregularities is such that the mat body is pulled and stretched in the longitudinal direction, and the plastic film is not pulled or stretched, and then the two are bonded together, and the plastic film is warped due to the contraction of the mat body.

[0053] (Embodiment 2) FIG. 3 is a diagram showing the appearance of the antibacterial and antiviral mat product according to this embodiment, and FIG. 4 is a cross-sectional end view taken along line CC' in FIG.

[0054] As shown in Figures 3 and 4, an antibacterial and antiviral mat product 100 according to the present invention is made of a natural rubber foam and includes a substantially rectangular parallelepiped mat body 10, and an antibacterial and antiviral coating layer 20 made of a plastic coating film formed in contact with the surface of the mat body 10. As shown in Figures 3 and 4, an uneven structure 11 for dispersing body pressure is formed on one of the sides having the largest area of ​​the mat body 10, and the antibacterial and antiviral coating layer 20 formed on this surface has an uneven shape 22 that follows this uneven structure.

[0055] In this embodiment as well, similarly to the above-mentioned first embodiment, high hygiene is ensured.

[0056] Furthermore, one of the sides of the mat body 10 with the largest area is formed with an uneven structure 11 for dispersing body pressure, so that when a person sits on the mat and uses it, body pressure is appropriately dispersed and breathability is ensured between the human body and the mat product, preventing discomfort during use.

[0057] The shape and method of forming the uneven structure are not particularly limited, and any known shape and manufacturing method can be used.

[0058] Example 1 A commercially available polycarbonate-based polyurethane film (polyurethane layer thickness 40 μm) that had been treated with an antibacterial and antiviral agent and had an adhesive layer formed on one side was attached to all surfaces of a commercially available natural rubber foam (1800 × 900 × 80 mm).When attaching to one of the largest surfaces, the natural rubber foam was stretched by 5% in the longitudinal direction (area stretched by 5%), and a film (1890 mm long) that was 5% longer in the longitudinal direction than the opposite surface was attached.

[0059] After the pulling force was removed, numerous wrinkle-like irregularities extending in a direction approximately perpendicular to the longitudinal direction were formed on the film. Through these operations, an antibacterial and antiviral mat product according to Example 1 was obtained, in which an antibacterial and antiviral coating layer made of polyurethane film was formed on a mat body made of a natural rubber foam. The wrinkle-like irregularities were 1.5 mm deepest, with a minimum interval of 2 mm and a maximum interval of 10 mm.

[0060] Example 2 A mat body was produced by forming a urethane foam in a mold (1800×900×80 mm) in which a concave-convex structure was formed on one of the sides with the largest area. This concave-convex structure is formed by regularly arranging cone-shaped convex portions with rounded apexes and concave portions, and each of the convex portions and concave portions is 20 mm high and 120 mm in size. A polycarbonate-based polyurethane film (the same as in Example 1) on which an adhesive layer was formed was attached to all surfaces of this mat body to produce an antibacterial and antiviral mat product according to Example 2.

[0061] In this case, when attaching to the uneven surface, a polycarbonate-based polyurethane film is placed on the uneven surface of the mat body so that the adhesive layer is in contact with the uneven surface, and the release layer on the opposite side of the adhesive layer is heated to 80 to 100°C with an iron, and then the release layer is peeled off, and the polyurethane film is pressed against the mat body side by hand to be pressed against the recesses, so that the polyurethane film is attached to the uneven structure without bending. As a result, the polyurethane film has an uneven shape that follows the uneven structure.

[0062] The uneven surfaces of the antibacterial and antiviral coating layers of the antibacterial and antiviral mat products according to Examples 1 and 2 were wiped 100 times with a wet tissue soaked in a 70% ethyl alcohol solution, and then wiped 100 times with a dustcloth soaked in a commercially available chlorine-based disinfectant (containing sodium hypochlorite, effective chlorine concentration 200 ppm). Visual inspection of the coating layer surface before and after wiping revealed no wear on the coating layer, confirming that it had high chemical resistance.

[0063] The mat product of the present invention is suitable for use in medical and nursing care settings, as well as in places where hygiene considerations are highly important, such as mat products for use by infants and spaces where pets are present.

[0064] The embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims, not by the above description, and is intended to include all modifications within the meaning and scope of the claims. For example, the antibacterial and antiviral mat product can be used hygienically enough even without a cover, and does not exclude the use of a cover or the like on the product. [Industrial Applicability]

[0065] The antibacterial and antiviral mat product according to the present invention can maintain high hygiene without using a cover or the like, and has great industrial applicability. [Explanation of symbols]

[0066] 100 Antibacterial and antiviral mat products 10 Mat body 11 Uneven structure 20 Antibacterial and antiviral coating layer 21 Fine irregularities 22 Uneven shape

Claims

1. A mat body made of a foaming material; and an antibacterial and antiviral plastic coating layer provided directly on all surfaces of the mat body; An antibacterial and antiviral mat product, wherein at least one surface of the antibacterial and antiviral coating layer has fine projections and recesses formed thereon.

2. A mat body made of a foaming material; and an antibacterial and antiviral plastic coating layer provided directly on all surfaces of the mat body; This is an antibacterial and antiviral mat product, wherein the mat body is approximately rectangular and one of its sides having the largest area has an uneven structure for dispersing body pressure.

3. The surface of the antibacterial and antiviral coating layer formed on the mat body surface on which the uneven structure is formed has fine unevenness formed thereon.

3. The antibacterial and antiviral mat product according to claim 2.

4. The antibacterial and antiviral coating layer is formed of a plastic film, The minute irregularities are formed by bending of the plastic film.

2. The antibacterial and antiviral mat product according to claim 1.

5. the ratio of the actual area of ​​the surface on which the fine irregularities are formed to the apparent area is 1.02 to 1.10; 5. The antibacterial and antiviral mat product according to claim 4.

6. The plastic film is a polycarbonate-based polyurethane film.

6. The antibacterial and antiviral mat product according to claim 4 or 5.

7. The mat body is made of a natural rubber foam.

6. An antibacterial and antiviral mat product according to claim 1.

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