Manufacturing method of cushion body
By overlapping and cutting block bodies to form concave and convex portions in cushion production, the method addresses the inefficiencies of existing multi-layer cushion manufacturing, achieving cost-effective and comfortable cushions with adjustable layer continuity.
Patent Information
- Application Number
- JP2023119054
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-07-21
- Publication Date
- 2025-01-31
AI Technical Summary
The existing methods for producing multi-layered cushions require time-consuming and costly cutting and assembly processes, necessitating improvements to reduce hassle and cost.
A method involving the production of cushion bodies by overlapping and cutting block bodies composed of first and second members, forming concave and convex portions, and adjusting the thickness of the members to create continuous or independent layers, using materials like urethane foam and solid cotton.
This approach allows for the efficient and cost-effective manufacturing of cushions with multiple layers, providing softness and support while reducing manufacturing time and effort.
Smart Images
Figure 2025016044000001_ABST
Abstract
Description
[Technical field]
[0001] The present disclosure relates to a method for manufacturing a cushioning body. [Background technology]
[0002] Patent Document 1 describes a mattress composed of an upper layer, a middle layer, and a lower layer. For the upper layer, a foam for the upper layer, which is the base of the upper layer, is passed between a pair of rolls arranged opposite each other. A profiling process is performed in which the foam for the upper layer is passed between a plurality of protrusions provided on each of the outer peripheral surfaces of the pair of rolls, and a corrugated shape is formed in the foam for the upper layer.
[0003] For the middle and lower layers, the above-mentioned profiling process is performed on a three-layer foam structure in which a middle layer foam that is the basis for the middle layer is sandwiched between two sheets of lower layer foam that are the basis for the lower layer and bonded together. This profiling process produces an intermediate product that includes a middle layer and a lower layer in which convex portions and concave portions are formed. The convex portion of the intermediate product is horizontally cut at a predetermined height position from the upper surface of the lower layer to produce a middle layer having a convex portion in the shape of a truncated quadrangular pyramid. The mattress is then manufactured by bonding the bottom surface of the upper layer to the upper surface of the convex portion in the shape of a truncated quadrangular pyramid of the middle layer. [Prior art documents] [Patent documents]
[0004] [Patent Document 1] JP 2016-215003 A Summary of the Invention [Problem to be solved by the invention]
[0005] In order to manufacture the foam with the above-mentioned middle and lower layers of the mattress integrated, it is necessary to cut the foam with the above-mentioned three-layer structure twice. Therefore, cutting and bonding are time-consuming and costly. It is required to reduce the manufacturing time and cost of a cushion body with multiple layers.
[0006] The present disclosure aims to provide a method for manufacturing a cushion body that can reduce effort and cost even when multiple layers are provided. [Means for solving the problem]
[0007] The method for manufacturing a cushion body according to the present disclosure is (1) a method for manufacturing a cushion body on which a user's body is placed. The method for manufacturing the cushion body includes the steps of: bonding a second member harder than the first member to a first member constituting the cushion body to produce a block body including the first member and the second member; overlapping one first member of the pair of block bodies with the other first member of the pair of block bodies; cutting the pair of block bodies along a cutting line that meanders up and down with respect to the boundary between one first member of the pair of block bodies and the other first member of the pair of block bodies; and removing the first member in a portion defined by the boundary and the cutting line extending upward from the boundary.
[0008] In this method for manufacturing a cushion body, the first member of the other of the pair of block bodies is superimposed on the first member of one of the pair of block bodies. Thus, the second member is located at the top, and the first member is located below the second member. Then, another first member is located below the first member, and another second member is located below the other first member. Also, one first member and the other first member are not bonded together. Therefore, by cutting the block bodies along a cutting line that meanders above and below the boundary, a plurality of recesses are formed in each of the pair of block bodies, and the top surfaces of the protrusions located between the adjacent recesses can be made flat. Therefore, a cushion body having a truncated pyramidal protrusion can be manufactured. After cutting the pair of block bodies along the cutting line, the first member in the portion defined by the boundary and the cutting line extending upward from the boundary can be removed to manufacture the cushion body. Therefore, a cushion body having a plurality of layers, such as a layer constituted by the first member of the block body and a layer constituted by the second member, can be easily manufactured, thereby reducing the effort and cost required for manufacturing.
[0009] (2) In the above (1), the first member may be made of urethane foam, and the second member may be made of solid cotton. Since the first member is made of urethane foam, the user can feel the softness when placing the body on the cushion body. Since the second member is made of solid cotton, the second member supports the user's body and prevents the body from sinking too much.
[0010] (3) In the above (1) or (2), the method for manufacturing the cushion body may include a step of selecting either of forming a plurality of first members that are continuous with each other as the upper surface of the cushion body by cutting the pair of block bodies, or forming a plurality of first members that are independent of each other as the upper surface of the cushion body by cutting the pair of block bodies. In this case, it is possible to appropriately select between manufacturing a cushion body in which the plurality of first members are continuous with each other and manufacturing a cushion body in which the plurality of first members are independent of each other.
[0011] (4) In the above (3), in the selecting step, it may be possible to select forming a plurality of first members that are continuous with each other as the upper surface of the cushion body by setting the thickness of the second member to N (mm) or less, where N is a positive real number, or to select forming a plurality of first members that are independent of each other as the upper surface of the cushion body by setting the thickness of the second member to be thicker than N (mm). In this case, by adjusting the thickness of the second member, it is possible to manufacture either a cushion body in which the plurality of first members are continuous with each other, or a cushion body in which the plurality of first members are independent of each other. By changing the thickness of the second member, it is possible to easily select a cushion body in which the plurality of first members are continuous with each other, or a cushion body in which the plurality of first members are independent of each other. Effect of the Invention
[0012] According to the present disclosure, it is possible to provide a method for manufacturing a cushion body that can reduce the effort and cost even when a cushion body has multiple layers. [Brief description of the drawings]
[0013] [Figure 1] FIG. 1 is a perspective view showing a cushion body manufactured by a manufacturing method for a cushion body according to an embodiment. [Diagram 2] FIG. 2 is a perspective view showing a cushion body manufactured by the manufacturing method for a cushion body according to the embodiment, which is different from the cushion body shown in FIG. [Diagram 3]FIG. 3 is a flow chart showing an example of steps in a method for manufacturing a cushion body. [Figure 4] FIG. 4 is a front view showing the block body. [Diagram 5] FIG. 5 is a diagram for explaining the overlapping step. [Figure 6] FIG. 6 is a diagram for explaining the cutting step. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Hereinafter, an embodiment of the manufacturing method of the cushion body according to the present disclosure will be described with reference to the drawings. In the description of the drawings, the same or corresponding elements are given the same reference numerals, and duplicated descriptions are omitted as appropriate. The drawings may be partially simplified or exaggerated for ease of understanding, and the dimensional ratios and the like are not limited to those shown in the drawings.
[0015] Each of the cushion bodies 1A and 1B shown in Fig. 1 and Fig. 2 is a cushion body selectively manufactured by the manufacturing method of the cushion body according to this embodiment. Fig. 1 is a perspective view of the cushion body 1A. Fig. 2 is a perspective view of the cushion body 1B. The body of a user is placed on the cushion bodies 1A and 1B. The cushion bodies 1A and 1B are used as, for example, a mattress, a futon, or a cushion. In this embodiment, an example in which the cushion bodies 1A and 1B are mattresses will be described. The cushion bodies 1A and 1B are used, for example, housed in a cover for preventing dirt. The cushion bodies 1A and 1B are made of a flexible material. The flexible material refers to a material that is soft enough to be deformed by the body being placed on it.
[0016] The cushion body 1A will be described below with reference to Fig. 1. The cushion body 1A has a long side 1a extending in a first direction D1 in a plan view and a short side 1b extending in a second direction D2 intersecting the first direction D1 in a plan view. In this embodiment, the first direction D1 indicates the longitudinal direction of the cushion body 1A, and the second direction D2 indicates the lateral direction (width direction) of the cushion body 1A. The cushion body 1A has a thickness in a third direction D3 that intersects both the first direction D1 and the second direction D2.
[0017] The cushion body 1A has an upper surface 1c facing the body of the user and a lower surface 1d facing the opposite side to the upper surface 1c. The cushion body 1A has a plurality of recesses 11 recessed from the upper surface 1c toward the lower surface 1d, and a plurality of protrusions 12 sandwiched between two adjacent recesses 11. When viewed from the second direction D2, the recesses 11 have a shape identical to, for example, a part of a sine wave. The recesses 11 may be parabolic. The protrusions 12 have a truncated pyramid shape. The tops of the protrusions 12 are flat surfaces. More specifically, the protrusions 12 have a quadrangular pyramid shape.
[0018] The multiple protrusions 12 are arranged at intervals from each other along the first direction D1. A recess 11 is formed between two adjacent protrusions 12 along the first direction D1. For example, the protrusions 12 and the recesses 11 are arranged alternately along the first direction D1. In a plan view (when viewed along the third direction D3), the multiple recesses 11 are arranged in a staggered manner, and the protrusions 12 are arranged in a staggered manner between the multiple recesses 11. On the upper surface 1c side of the cushion body 1A, multiple sets of recesses 11 and protrusions 12 arranged alternately along the first direction D1 are arranged along the second direction D2.
[0019] The above-mentioned multiple sets include a first set in which the convex portions 12 and the concave portions 11 are alternately arranged in this order from the short side 1b along the first direction D1, and a second set in which the concave portions 11 and the convex portions 12 are alternately arranged in this order from the short side 1b along the first direction D1. The first set is adjacent to the second set in the second direction D2. The first set and the second set are alternately arranged along the second direction D2. As a result, the convex portions 12 and the concave portions 11 are alternately arranged along the second direction D2. The multiple convex portions 12 are arranged along an oblique direction that is a direction extending along the upper surface 1c and a direction intersecting both the first direction D1 and the second direction D2. Hereinafter, the "oblique direction that is a direction extending along the upper surface 1c and a direction intersecting both the first direction D1 and the second direction D2" may be simply referred to as an "oblique direction". In the cushion body 1A, two protrusions 12 adjacent to each other in the diagonal direction are not connected to each other and are independent of each other.
[0020] In this specification, a "recess" refers to a portion surrounded by lines on all four sides in a plan view (as viewed from the third direction D3) and deeper than the lines. In a plan view, the lines surrounding the four sides may be separated from other lines surrounding the four sides. The "recess" may be open in at least one of the first direction D1 and the second direction D2. An example of a recess that is open in at least one of the first direction D1 and the second direction D2 is recess 11 located at at least one of the ends in the first direction D1 and the second direction D2.
[0021] The cushion body 1A comprises an upper layer 2 against which the user's body rests, and a lower layer 3 located below the upper layer 2. The lower layer 3 has a rectangular shape when viewed from the bottom. The lower layer 3 is made of a different material from the upper layer 2. The lower layer 3 is made of a flexible material. The lower layer 3 is made of a material that is harder than the upper layer 2. The lower layer 3 is made of, for example, solid cotton. In this case, the lower layer 3 may be made of a polyester solid cotton material.
[0022] The lower layer 3 has a main body 31 extending in both the first direction D1 and the second direction D2, and a plurality of convex bases 32. The main body 31 is a portion located below the convex bases 32. For example, the upper surface of the main body 31 is the bottom surface of the recess 11. The main body 31 has a rectangular shape when viewed from the bottom. For example, the main body 31 has a flat plate shape. The surface of the main body 31 facing away from the surface facing the user is the lower surface 1d.
[0023] For example, the upper surface of the convex base 32 is a flat surface. The convex base 32 constitutes a part of the convex portion 12. The convex base 32 constitutes a lower portion of the convex portion 12. The convex base 32 is a part that protrudes upward from the upper surface of the main body 31 (the bottom surface of the recess 11). The convex base 32 has a shape identical to a part of a sine wave when viewed from the second direction D2, for example. The convex base 32 may have a parabolic shape. For example, the upper surface of the convex base 32 is parallel to the lower surface 1d. In this case, the upper surface of the convex base 32 extends in both the first direction D1 and the second direction. The main body 31 and the multiple convex bases 32 are integrated. In the cushion body 1A, two convex bases 32 adjacent to each other in a diagonal direction are not connected and are independent of each other.
[0024] The upper layer 2 is connected to the lower layer 3 on the upper side thereof. More specifically, the upper layer 2 has a plurality of convex tip portions 21, which are laminated on the upper side of the convex base portion 32. The convex tip portions 21 form part of the convex portion 12. The convex tip portions 21 form the upper portion of the convex portion 12. The convex portion 12 is composed of the convex base portion 32 and the convex tip portions 21 attached to the upper surface of the convex base portion 32.
[0025] The plurality of protrusion tips 21 and the plurality of protrusion bases 32 correspond one-to-one, and one protrusion tip 21 is stacked on one protrusion base 32. The protrusion tip 21 has a quadrangular pyramid shape. The lower surface of the protrusion tip 21 has a rectangular shape, and the size (area) of the lower surface of the protrusion tip 21 is the same as the size of the upper surface of the protrusion base 32. For example, the upper surface of the protrusion tip 21 has a rectangular shape, and the area of the upper surface of the protrusion tip 21 is smaller than the area of the lower surface of the protrusion tip 21. The side surface of the protrusion tip 21 (the surface facing the direction intersecting the third direction D3) is smoothly connected to the side surface of the protrusion base 32. For example, the shape of the protrusion tip 21 when viewed along the second direction D2 is the same as the shape of a part of a sine wave.
[0026] As described above, the convex tip portions 21 are stacked on the upper side of the convex base portions 32. Thus, the multiple convex tip portions 21 are arranged in a diagonal direction, similar to the convex base portions 32. The upper surfaces 21a of two convex tip portions 21 adjacent to each other in a diagonal direction are not connected to each other. That is, in the cushion body 1A, the multiple convex tip portions 21 are independent of each other. The upper surfaces 21a of the convex tip portions 21 form the upper surface 1c of the cushion body 1A.
[0027] For example, in the cushion body 1A, the upper surface of the protrusion 12 (upper surface 21a of the protrusion tip portion 21) has a rectangular shape. As an example, the length of the upper surface of the protrusion 12 in the first direction D1 is shorter than the length of the upper surface of the protrusion 12 in the second direction D2. However, the length of the upper surface of the protrusion 12 in the first direction D1 may be the same as the length of the upper surface of the protrusion 12 in the second direction D2, or may be longer than the length of the upper surface of the protrusion 12 in the second direction D2.
[0028] The upper layer 2 is made of a flexible material. The upper layer 2 is made of a material softer than the lower layer 3. The upper layer 2 is made of, for example, urethane foam. The upper layer 2 may be made of biomass urethane or a soft foamable resin material (memory foam, polyethylene foam, membrane-free foam, or latex (natural rubber), polyester solid cotton material, or one that can be cut with a two-dimensional processing machine).
[0029] Next, the cushion body 1B will be described with reference to Fig. 2. Since part of the configuration of the cushion body 1B overlaps with part of the configuration of the cushion body 1A, hereinafter, the same reference numerals will be used and the description that overlaps with the contents of the cushion body 1A will be omitted as appropriate. In the cushion body 1B, two adjacent protrusion bases 32 along a diagonal direction are connected to each other, and the upper surfaces 21a of two adjacent protrusion tip portions 21 along a diagonal direction are connected to each other.
[0030] In the cushion body 1B, the upper surfaces of the protrusions 12 (upper surfaces 21a of the protrusion tip portions 21) are continuous with each other. In the cushion body 1B, the upper surfaces of the protrusions 12 are rectangular, and at least one of the multiple corners on the upper surface of the protrusions 12 is continuous with the upper surfaces of the other protrusions 12. As an example, all or part of the four corners of the upper surface of the protrusions 12 are continuous with the upper surfaces of the other protrusions 12.
[0031] One or two corners of the upper surface of the protrusion 12 located at the end in the first direction D1 (one or two corners located toward the center of the cushion body 1B in the first direction D1 in a plan view) are continuous with the upper surface of the protrusion 12 adjacent to the protrusion 12 in the first direction D1. One or two corners of the upper surface of the protrusion 12 located at the end in the second direction D2 (one or two corners located toward the center of the cushion body 1B in the second direction D2 in a plan view) are continuous with the upper surface of the protrusion 12 adjacent to the protrusion 12 in the second direction D2. The four corners of the upper surface of the protrusion 12 other than the protrusion 12 located at the end in the first direction D1 and the protrusion 12 located at the end in the second direction D2 are continuous with the upper surface of the protrusion 12 adjacent to the protrusion 12.
[0032] An example of a method for manufacturing a cushion body according to this embodiment will be described with reference to Fig. 3. Fig. 3 is a flowchart showing an example of steps of the method for manufacturing a cushion body. The method for manufacturing a cushion body may be used when manufacturing the cushion bodies 1A and 1B described above, or may be used when manufacturing a cushion body other than the cushion bodies 1A and 1B.
[0033] First, a first member B1 and a second member B2 constituting a block body B shown in Fig. 4 are prepared. Fig. 4 is a front view showing the block body B. The block body B includes a first member B1 constituting an upper layer 2 and a second member B2 constituting a lower layer 3. The first member B1 and the second member B2 are flat plate-shaped members. The first member B1 is stacked on the upper side of the second member B2.
[0034] The second member B2 is made of a material different from the first member B1. The second member B2 is made of a material harder than the material making up the first member B1. The first member B1 is made of, for example, urethane foam. The first member B1 may be made of membrane-free urethane. The second member B2 is made of, for example, solid cotton. For example, the length (thickness) of the first member B1 in the third direction D3 is a thickness d1. The length (thickness) of the second member B2 in the third direction D3 is a thickness d2 that is greater than the thickness d1.
[0035] The method for manufacturing a cushion body according to this embodiment makes it possible to manufacture different types of cushion bodies by adjusting the thickness d2 of the second member B2 relative to the thickness d1 of the first member B1. In this embodiment, the cushion body is manufactured based on the knowledge that when the ratio of the thickness d2 to the thickness d1 is equal to or greater than a certain value, a cushion body 1A having upper surfaces independent of each other is manufactured, and when the ratio of the thickness d2 to the thickness d1 is not equal to or greater than the certain value, a cushion body 1B having upper surfaces continuous with each other is manufactured.
[0036] In this embodiment, a selection is made between the cushion bodies 1A and 1B to be produced (a selection process, step S1). More specifically, a selection is made between forming a continuous upper surface 21a as the upper surface of the cushion body as in the cushion body 1B, and forming separate upper surfaces 21a as the upper surface of the cushion body as in the cushion body 1A.
[0037] In this embodiment, the thickness d2 of the second member B2 is determined to select whether to manufacture the cushion body 1A or the cushion body 1B. For example, the cushion body 1B is selected to be manufactured by setting the thickness d2 to N mm or less while keeping the thickness d1 constant, where N is a positive real number, and the cushion body 1A is selected to be manufactured by setting the thickness d2 to N mm or less while keeping the thickness d1 constant.
[0038] As in the cushion body 1A, a combination of thickness d1 and thickness d2 for forming an upper surface 21a that is independent of each other as the upper surface of the cushion body may be, for example, a case where thickness d1 is 10 mm or 20 mm and thickness d2 is 50 mm. In other words, the cushion body 1A is manufactured when thickness d1 is 20 mm or less and thickness d2 is 50 mm.
[0039] On the other hand, as in the cushion body 1B, a combination of thickness d1 and thickness d2 for forming a continuous upper surface 21a as the upper surface of the cushion body may be, for example, a case where thickness d1 is 10 mm or 20 mm and thickness d2 is 30 mm. That is, the cushion body 1B is manufactured when thickness d1 is 20 mm or less and thickness d2 is 30 mm. A second member B2 having a thickness d2 of 20 mm or more and less than 30 mm may be used to manufacture the cushion body 1B.
[0040] Then, the first member B1 is layered on the second member B2 to produce a block body B (a fabrication process, step S2). More specifically, the first member B1 is attached to the second member B2 so that the first member B1 is layered on the second member B2 to produce the block body B. For example, the first member B1 is bonded and fixed onto the second member B2 with an adhesive.
[0041] Next, as shown in Fig. 5, the first member B1 of one of the pair of block bodies B is overlapped with the first member B1 of the other of the pair of block bodies B (overlapping process, step S3). Fig. 5 is a diagram for explaining step S3. In more detail, a pair of block bodies B is first prepared. Next, one of the pair of block bodies B is placed on the other of the pair of block bodies B so that the first member B1 of one block body B and the first member B1 of the other block body B face each other.
[0042] At this time, the pair of block bodies B are not attached to each other. That is, the pair of block bodies B are not fixed to each other, and one block body B is simply placed on the other block body B (not fixed by adhesive or the like). Between one first member B1 of the pair of block bodies B and the other first member B1 of the pair of block bodies B, a boundary BL is formed, which is a placement surface where one block body B is placed on the other block body B.
[0043] Next, the pair of block bodies B are cut (cutting process, step S4). FIG. 6 is a diagram for explaining step S4. More specifically, the pair of block bodies B are cut along a cutting line CL that meanders up and down with respect to the boundary BL. The cutting line CL is formed, for example, so as to meander in one direction (upward) in a third direction D3 and in the other direction (downward) in the third direction D3 with respect to the boundary BL as it proceeds in the first direction D1. As an example, the cutting line CL has a sine wave shape when viewed in the second direction D2.
[0044] The pair of block bodies B is cut along the cutting line CL by, for example, a profile processing machine. In this case, the pair of block bodies B is passed between the uneven portions formed on the surfaces of a pair of rollers of the profile processing machine, and the pair of block bodies B is cut while pressing the pair of block bodies B with the uneven portions in the direction in which the pair of rollers are aligned, thereby achieving cutting of the pair of block bodies B along the cutting line CL.
[0045] After cutting the pair of block bodies B, the portion defined by the boundary BL and the cutting line CL is removed (removing process, step S5). More specifically, in step S5, at least the first member B1 in the portion B3 defined by the boundary BL and the cutting line CL extending upward from the boundary BL is removed. When the cutting line CL passes through the second member B2, the first member B1 and the second member B2 located in the portion defined by the boundary BL and the cutting line CL extending upward from the boundary BL are removed by removing the portion B3.
[0046] In step S5, the first member B1 may be removed in a portion B4 defined by the boundary BL and the cutting line CL extending downward from the boundary BL. If the cutting line CL passes through the second member B2, the first member B1 and the second member B2 located in the portion defined by the boundary BL and the cutting line CL extending downward from the boundary BL are removed by removing the portion B4.
[0047] Next, the effect of the manufacturing method of the cushion body of this embodiment will be described. In this manufacturing method of the cushion body, the first member B1 of one of the pair of block bodies B is superimposed on the first member B1 of the other of the pair of block bodies B. Therefore, the second member B2 is located at the top, and the first member B1 is located below the second member B2. Then, another first member B1 is located below the first member B1, and another second member B2 is located below the other first member B1. In addition, one first member B1 and the other first member B1 are not bonded together. Therefore, by cutting the block body B along the cutting line CL that meanders above and below the boundary BL, a plurality of recesses 11 are formed in each of the pair of block bodies B, and the top surfaces of the protrusions 12 located between the adjacent recesses 11 become flat. Therefore, it is possible to manufacture cushion bodies 1A and 1B having truncated pyramidal protrusions.
[0048] After cutting the pair of block bodies B along the cutting line, the first member B1 in the portion defined by the boundary BL and the cutting line CL extending upward from the boundary BL is removed to produce the cushion bodies 1A, 1B. Therefore, the cushion bodies 1A, 1B having multiple layers, such as the upper layer 2 formed by the first member B1 of the block body B and the lower layer 3 formed by the second member B2, can be easily manufactured, thereby reducing the effort and cost required for manufacturing.
[0049] The first member B1 is made of urethane foam. The second member B2 is made of solid cotton. Since the first member B1 is made of urethane foam, the user can feel the softness when he / she places his / her body on the cushion body 1A, 1B. Since the second member B2 is made of solid cotton, the second member B2 supports the user's body and prevents the user's body from sinking too deeply. In other words, when the user places his / her body on the cushion body 1A, 1B, the convex tip portion 21 can feel the softness, and the convex base portion 32 and the main body portion 31 can support the user's body and prevent the user's body from sinking too deeply.
[0050] The method for manufacturing the cushion body includes a step of selecting either of forming a plurality of first members B1 (protruding tip portions 21) that are continuous with each other as the upper surface 1c of the cushion body 1B by cutting a pair of block bodies B, or forming a plurality of first members B1 (protruding tip portions 21) that are independent of each other as the upper surface 1c of the cushion body 1A by cutting a pair of block bodies B. In this case, it is possible to appropriately select between manufacturing the cushion body 1B in which the plurality of first members B1 are continuous with each other, and manufacturing the cushion body 1A in which the plurality of first members B1 are independent of each other.
[0051] In the selection step (step S1), by setting the thickness d2 of the second member B2 to N (mm) or less, where N is a positive real number, it is selected to form a plurality of first members B1 (protruding tip portions 21) that are continuous with each other as the upper surface 1c of the cushion body 1B, and by setting the thickness d2 of the second member B2 to be thicker than N (mm), it is selected to form a plurality of first members B1 (protruding tip portions 21) that are independent of each other as the upper surface 1c of the cushion body 1A. In this case, by adjusting the thickness d2 of the second member B2, it is possible to manufacture either a cushion body 1B in which a plurality of first members B1 are continuous with each other, or a cushion body 1A in which a plurality of first members B1 are independent of each other. By changing the thickness d2 of the second member B2, it is possible to easily select a cushion body 1B in which a plurality of first members B1 are continuous with each other, or a cushion body 1A in which a plurality of first members B1 are independent of each other.
[0052] The above describes an embodiment of the manufacturing method of the cushion body according to the present disclosure. However, the present invention is not limited to the above embodiment, and may be modified or applied to other things without changing the gist of the claims. In other words, the shape, size, material, number and arrangement of each part of the cushion body and block body according to the present disclosure can be modified in various ways without changing the gist of the claims.
[0053] In step S1, which is a selection process, by determining the hardness of the first member B1 and the hardness of the second member B2 instead of or in addition to the thickness d2 of the second member B2, it is possible to select either cutting the pair of block bodies B to form a plurality of continuous first members B1 as the upper surface of the cushion body, or cutting the pair of block bodies B to form a plurality of independent first members B1 as the upper surface of the cushion body.
[0054] After step S5, through-holes penetrating the cushion bodies 1A, 1B so as to extend in the third direction D3 may be formed in the bottom of the recess 11. In this case, even when the user is lying on the cushion bodies 1A, 1B, the breathability between the user and the cushion bodies 1A, 1B is improved.
[0055] After step S5, a plurality of slits recessed from the lower surface 1d toward the upper surface 1c in the third direction D3 may be formed in the lower surface 1d. In this case, the weight of the body of the user lying on the cushion bodies 1A and 1B can be more effectively distributed, thereby improving the cushioning properties.
[0056] This method of manufacturing the cushion body may further include a step of selecting to form the protrusion base 32 of the second member B2 by making the thickness d1 of the first member B1 equal to or smaller than M (mm), where M is a positive real number, and selecting not to form the protrusion base 32 of the second member B2 by making the thickness d1 of the first member B1 thicker than M (mm). However, this step is subject to the condition that the amplitude of the cutting line CL is constant.
[0057] In the above process, by bringing the thickness d1 closer to 0 (mm), it is possible to shorten the length (thickness) of the protruding portion tip 21 in the third direction D3. Also, by bringing the thickness d1 closer to M (mm), it is possible to thicken the protruding portion tip 21. Also, by making the thickness d1 M (mm), it is possible to form the entire protruding portion 12 from the same material as the first member B1. By making the thickness d1 larger than M (mm), it is possible to form the entire protruding portion 12 from the same material as the first member B1, and also to form the upper end side of the portion called the main body portion 31 from the same material as the first member B1. In this way, various cushion bodies can be manufactured by adjusting the thickness d1.
[0058] The cushion body 1A having a thickness d1 of 10 mm and a thickness d2 of 50 mm may be used in a state in which it is placed on a cushion body having a thickness of 30 mm. The cushion body may be made of solid cotton. A recess may be formed on either the upper surface or the lower surface of the cushion body. In this case, the breathability of the space below the cushion body 1A can be improved. [Explanation of symbols]
[0059] 1A, 1B...cushion body, 1a...long side, 1b...short side, 1c...upper surface, 1d...lower surface, 2...upper layer, 3...lower layer, 11...recess, 12...convex portion, 21...tip of convex portion, 21a...upper surface, 31...main body, 32...base of convex portion, B...block body, B1...first member, B2...second member, B3...portion, B4...portion, d1, d2...thickness, D1...first direction, D2...second direction, D3...third direction, BL...boundary, CL...cutting line.
Claims
1. A manufacturing method of a cushion body on which a user's body can be placed, comprising the steps of: a step of bonding a second member harder than a first member constituting the cushion body to the first member to produce a block body including the first member and the second member; a step of overlapping the first member of one of the pair of block bodies with the first member of the other of the pair of block bodies; cutting the pair of block bodies along a cutting line that meanders up and down with respect to a boundary between the first member of one of the pair of block bodies and the first member of the other of the pair of block bodies; removing the first member in a portion defined by the boundary and the cut line extending upwardly from the boundary; Equipped with A method for manufacturing a cushion body.
2. The first member is made of urethane foam, The second member is made of solid cotton. A method for manufacturing the cushion body according to claim 1.
3. cutting the pair of block bodies to form a plurality of the first members that are continuous with each other as an upper surface of the cushion body; and cutting the pair of block bodies to form a plurality of the first members that are independent of each other as an upper surface of the cushion body; The method includes the step of selecting one of the following: A method for manufacturing the cushion body according to claim 1 or 2.
4. In the selecting step, N is a positive real number, The thickness of the second member is set to N (mm) or less, and a plurality of the first members are formed as an upper surface of the cushion body, the plurality of first members being continuous with each other; By making the thickness of the second member thicker than N (mm), a plurality of the first members independent from each other are formed as the upper surface of the cushion body. A method for manufacturing the cushion body according to claim 3.
Citation Information
Patent Citations
Mattress
JP2016215003A