Mattress

Abstract

To provide a mattress having hygroscopic properties and / or moisture-releasing properties.SOLUTION: A mattress 1 is formed in a substantially rectangular solid-like shape having a predetermined thickness in a thickness direction, and expanding in a longitudinal direction and a width direction. The mattress 1 comprises a resin foam 3 and a fiber body 4. The resin foam 3 is separated into a plurality of portions, and a boundary 5 is formed between the adjacent resin foams 3. The fiber body 4 is adhered to the resin foam 3 in a state of being disposed at least in a part of the boundary 5, and exposed at least to one surface in the thickness direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mattress.

Background Art

[0002] Conventionally, various mattresses or turning assist pads have been proposed. For example, according to Patent Document 1, a turning assist pad is a turning assist pad that is placed on a mattress, futon, or mat and used. This turning assist pad includes at least a first pad disposed in the body length direction on which the upper body side of the user is placed, and a second pad on which at least the waist and hip parts on the lower body side of the user are placed. The first pad is formed of a cushion material with a predetermined thickness and is configured to support at least a part of the back of the user in the supine position. The second pad is formed of a cushion material with a predetermined thickness. A second support portion having a width narrower than the width of the user's pelvis is provided at the center in the width direction of the second pad. At both ends in the width direction of the second pad, a pair of second hardness gradient portions are provided on at least a part of the length direction of the second support portion. The second hardness gradient portion has a second hardness adjustment means for adjusting so that a hardness gradient in which the apparent hardness gradually decreases is formed from the end of the second support portion outward. The second support portion supports at least a part of the waist and hip parts of the user in the supine position, and the second hardness gradient portion is configured to support the greater trochanter of the user's femur when turning over.

[0003] Also, it is preferable that the turning assist pad of the present invention is provided with a first support portion having a width equal to or less than the shoulder width of the user at the center in the width direction of the first pad, and a pair of first hardness gradient portions are provided on at least a part of the length direction of the first support portion at both ends in the width direction of the first pad. The first hardness gradient portion has a first hardness adjustment means for adjusting so that a hardness gradient in which the apparent hardness gradually decreases is formed from the end of the first support portion outward. The first support portion supports at least a part of the back of the user in the supine position, and the first hardness gradient portion is configured to support the shoulder of the user when turning over.

[0004] In addition, the cushioning material is not particularly limited as long as it has the above-described hardness and cushioning properties, but resin foams, three-dimensional network structures, and cotton molded bodies are preferably used, and resin foams are more preferable from the viewpoints of ease of handling and processing. Specific examples of the resin foam include foamed polyurethane, foamed polyolefin, or foamed silicone. Also, the first and second cushioning materials may be the same material as each other or different materials.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, the following problems are assumed for the auxiliary pad described in Patent Document 1. The cushioning materials of the first pad and the second pad are described as resin foams, and specific examples include foamed polyurethane, foamed polyolefin, or foamed silicone. These materials generally have poor moisture absorption and moisture release properties. Therefore, there are problems that when a user in contact with the auxiliary pad sweats or the like, it is not absorbed, or the auxiliary pad condenses. Although Patent Document 1 describes an auxiliary pad, the same problems are assumed even when applied to a mattress.

[0007] An object of the present invention is to provide a mattress having moisture absorption and / or moisture release properties.

Means for Solving the Problems

[0008] The mattress according to the first aspect of the present invention is a mattress having a predetermined thickness in the thickness direction and formed in a substantially rectangular parallelepiped shape extending in the longitudinal direction and the width direction, and includes a resin foam and a fibrous body. The resin foam is separated into a plurality of parts, and a boundary part is formed between the adjacent resin foams. The fibrous body is disposed at at least a part of the boundary part and is adhered to the resin foam in a state of being exposed on at least one surface in the thickness direction.

[0009] According to this, since the fibrous body is exposed on at least one surface in the thickness direction of the mattress, the mattress has hygroscopicity and / or moisture permeability. Since the fibrous body is formed at the boundary part of the resin foam, it can be adhered to the adjacent resin foam in the manufacturing process. Therefore, a mattress having hygroscopicity and / or moisture permeability can be easily manufactured.

[0010] Further, the fibrous body may be exposed on both surfaces in the thickness direction and communicate with one surface and the other surface. In this case, since the fibrous body is exposed on both surfaces in the thickness direction and communicates with one surface and the other surface, it has higher hygroscopicity and moisture permeability.

[0011] Further, the adjacent resin foams of the mattress may have different hardnesses. In this case, the resin foam can improve the feeling of use more by making the hardness appropriate according to the user's body part.

[0012] Further, the resin foam is separated into five or more odd-numbered parts along the longitudinal direction, and among the plurality of parts arranged in the width direction, the central part and the both-end parts may have the same hardness. In this case, the user can turn over in the same feeling to both sides in the width direction centering on the central row in the width direction.

[0013] Further, the both-end parts and the central part of the mattress may have a higher hardness than the other parts arranged adjacent to them.

[0014] In this case, the hardness of the resin foam is higher at both end portions and the central portion than at other portions. Therefore, the user can easily turn over laterally from the center in the width direction towards the end and can easily turn over again towards the center in the supine position, so the turn-over performance is further improved.

Brief Description of the Drawings

[0015]

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Embodiments for Carrying Out the Invention

[0016] Hereinafter, with reference to the drawings, the mattress 1 embodying the present invention will be described. The embodiments for carrying out the invention and the drawings referred to are used to explain the technical features that the present invention can adopt. The present invention is not limited to these. The configurations described in the drawings are not intended to be limited thereto, but are merely illustrative examples.

[0017] <<Common content among embodiments of the mattress 1 according to the first aspect>> The common content among the embodiments of the mattress 1 according to the first aspect of the present invention will be described. The mattress 1 according to the first aspect is the content exemplified by FIGS. 1 to 16. As shown in FIGS. 1 and the like, the mattress 1 has a predetermined thickness in the thickness direction and is formed in a substantially rectangular parallelepiped shape extending in the longitudinal direction and the width direction. The mattress 1 includes a resin foam 3 and a fibrous body 4. The resin foam 3 is separated into a plurality of parts, and a boundary portion 5 is formed between adjacent resin foams 3. The fibrous body 4 is disposed at at least a part of the boundary portion 5 and is adhered to the resin foam 3 in a state of being exposed on at least one surface in the thickness direction.

[0018] The resin foam 3 includes, for example, polyurethane foam, polyethylene foam, and foams of other resins. The polyurethane foam may be a film-free urethane foam or a film-coated urethane foam, and more preferably, a film-free urethane foam is preferred. The film-free urethane foam provides high air permeability. Generally, urethane foam contains a large number of cells in the urethane skeleton. These a large number of cells have a film between adjacent cells. However, by adjusting the material or its formulation of the urethane foam, a skeletal structure in which many films do not exist can be formed. Alternatively, a skeletal structure in which many films do not exist can be formed by subjecting the formed urethane foam to physical or chemical treatment. The film-free urethane foam may be a urethane foam in which at least 50% of the films defining the cells do not exist.

[0019] The fibrous body 4 is formed of, for example, non-woven fabric, woven fabric, or other fibers. The fibers may include cotton, hemp, wool, silk, polyester, polypropylene, polyethylene, aramid, vinylon, vinylidene, polyvinyl chloride, polyurethane, polyvinylidene chloride, polylactic acid, rayon, nylon, acrylic, or other natural fibers or synthetic fibers. The fibrous body 4 includes those having functionality by chemical modification or physical modification of these fibers. In particular, it is desirable that the fibrous body 4 is formed of highly water-absorbent and highly moisture-absorbent fibers obtained by directly spinning a polymer having sodium polyacrylate salt as a main component into a fibrous shape. The fibrous body 4 includes a large number of fibers and forms a large number of internal spaces between adjacent fibers. The fibrous body 4 absorbs moisture in a high-humidity environment and retains it in the internal spaces, and releases the moisture retained in the internal spaces in a low-humidity environment. Further, in addition to high moisture absorption and release properties, the fibrous body 4 includes good deodorizing properties, high antibacterial properties, or other high-functional properties, and provides high comfort. The basis weight of the fibrous body 4 is 10 g / m 2 ~4000 g / m 2 may be sufficient.

[0020] In the example shown in FIG. 4 and the like, the short-direction dimension of the fibrous body 4 is set to be shorter than the short-direction dimension of the resin foam 3. The short-direction dimension refers to, for example, the dimension in the direction perpendicular to the extending direction when the fibrous body 4 is formed to extend along the longitudinal direction. The same applies when the fibrous body 4 is formed to extend in the width direction. Further, the same applies when the fibrous body 4 extends while being inclined at a predetermined angle with respect to the longitudinal direction or the width direction. This is because the fibrous body 4 tends to have high hardness, and when the short-direction dimension increases, the hardness of the entire mattress 1 tends to increase. For example, the short-direction dimension of the fibrous body 4 in FIG. 4 is about 10 to 20 mm.

[0021] The adjacent resin foams 3 are separated into a plurality of parts by the boundary parts 5 and include various forms. Details will be described for each embodiment, but in the example shown in FIG. 1 and the like, the resin foams 3 are arranged in a plurality of rows along the longitudinal direction. In the example shown in FIG. 2 and the like, the resin foams 3 are arranged in a plurality of rows along the width direction. In the example shown in FIG. 6 and the like, the resin foams 3 are arranged in a lattice pattern in a plurality of rows along the longitudinal direction and the width direction. Although not shown further, the resin foams 3 may be arranged so as to intersect with a predetermined angle with respect to the longitudinal direction and the width direction. Further, the resin foams 3 may be separated while the boundary parts 5 form a polygon. For example, it may be separated into a honeycomb shape. Note that the direction along the longitudinal direction or the direction along the width direction does not necessarily exactly match the longitudinal direction or the width direction of the mattress 1, respectively, and includes those with an inclination within the scope of common technical knowledge.

[0022] In the example shown in FIG. 3(a) and the like, the fibrous body 4 is formed to be exposed on one surface in the thickness direction. Further, in the example shown in FIG. 3(b) and the like, the fibrous body 4 is formed to be exposed on one surface and the other surface in the thickness direction, and the fibrous bodies 4 are separated from each other.

[0023] On the other hand, in the example shown in FIG. 3(c), the fibrous body 4 is exposed on both surfaces in the thickness direction and communicates with one surface and the other surface. The individual forms of the fibrous body 4 and the boundary part 5 in each embodiment of the mattress 1 will be described later.

[0024] The resin foams 3 arranged adjacent to each other are, as shown in FIG. 3(a), in a state of being adhered via the fibrous body 4 in between on the first side in the thickness direction. On the second side in the thickness direction, the resin foams 3 are directly adhered to each other without passing through the fibrous body 4. FIG. 3 shows an example of the combination of the resin foam 3 and the fibrous body 4, but the adjacent resin foams 3 are either in a state of being directly adhered to each other or adhered via the fibrous body 4 in between.

[0025] In addition, the resin foams 3 arranged adjacent to each other have different hardnesses. When comparing adjacent resin foams 3, one has a higher hardness than the other. In the example shown in FIG. 1 and the like, the resin foams 3 are arranged along the longitudinal direction. However, as shown in FIG. 3 and the like, in the width direction, in each column, a high-hardness body 3a with a high hardness and a low-hardness body 3b with a low hardness are alternately formed. In the example shown in FIG. 2 and the like, the resin foams 3 are arranged along the width direction. However, as shown in FIG. 3 and the like, in the longitudinal direction, in each column, a high-hardness body 3a with a high hardness and a low-hardness body 3b with a low hardness are alternately formed.

[0026] The hardness of the high-hardness body 3a is, for example, in the range from 150 N to 250 N, and the hardness of the low-hardness body 3b is, for example, in the range from 90 N to 140 N. Note that the hardness of the high-hardness body 3a and the hardness of the low-hardness body 3b are not limited to these ranges, as long as the relationship that the hardness of the high-hardness body 3a is higher than the hardness of the low-hardness body 3b holds. The hardness is measured by the measurement standard JIS K 6400-2D method (40% compression). The hardness measurement described below is also by the same method. Note that the hardness value is an example, and even if it is outside this range, there should be a difference between the high-hardness body 3a and the low-hardness body 3b.

[0027] In the example shown in FIG. 3 and the like, the resin foams 3 are arranged in order from the left in the figure as the first-column resin foam 31, the second-column resin foam 32, the third-column resin foam 33, the fourth-column resin foam 34, and the fifth-column resin foam 35. The first-column resin foam 31, the third-column resin foam 33, and the fifth-column resin foam 35 are high-hardness bodies 3a, and the second-column resin foam 32 and the fourth-column resin foam 34 are low-hardness bodies 3b. As already described with reference to FIG. 4 and the like, in the width direction or the longitudinal direction, the fibrous body 4 is formed at the boundary portion 5, and the short-direction dimension of the fibrous body 4 is set to be shorter than the short-direction dimension of the resin foam 3. Thereby, the hardness difference between the high-hardness body 3a and the low-hardness body 3b can be clarified. This is because if the short-direction dimension of the fibrous body 4 is large and the hardness of the fibrous body 4 becomes equal to or higher than that of the high-hardness body 3a, it will be in a state contrary to the design intention. This applies to any of the cases where the fibrous body 4 is on only the first side in the thickness direction, only the second side, or communicates with the surface of the first side and the surface of the second side.

[0028] As already described, in the example shown in FIG. 6 and the like, the resin foam 3 is arranged along the longitudinal direction and the width direction. Although not shown, the resin foam 3 may be arranged so as to intersect with a predetermined angle with respect to the longitudinal direction and the width direction. Further, for example, the resin foam 3 may be arranged so that the boundary portion 5 forms a polygon. In any case, in the adjacent resin foams 3, a high-hardness body 3a having a high hardness and a low-hardness body 3b having a low hardness are alternately formed. Details will be described for each embodiment. For example, in the case shown in FIG. 6, the adjacent resin foams 3 are arranged in units of columns arranged along either the longitudinal direction or the width direction, and the hardness may be different between adjacent columns. Alternatively, the adjacent resin foams 3 may not be in column units, and the hardness of the adjacent resin foams 3 may be different with the boundary portion 5 as a boundary.

[0029] <<Common effects of each embodiment according to the first aspect>> According to the common content of each embodiment according to the first aspect described above, the following effects are obtained. As shown in FIG. 3 and the like, since the fibrous body 4 is exposed on at least one surface in the thickness direction of the mattress 1, it has hygroscopicity and / or moisture permeability. Since the fibrous body 4 is formed at the boundary portion 5 of the resin foam 3, it can adhere to the adjacent resin foam 3 in the manufacturing process. Therefore, the mattress 1 having hygroscopicity and / or moisture permeability can be easily manufactured.

[0030] Also, as shown in FIG. 3(c) and the like, if the fibrous body 4 is exposed on both surfaces in the thickness direction and is configured to communicate between one surface and the other surface, the first side surface and the second side surface are connected by the fibrous body 4. Therefore, in the thickness direction, the fibrous body 4 is exposed on both the surface in contact with the body and the installation surface, so that the hygroscopicity against sweating is improved, and further, the dew condensation on the installation surface can be reduced. Further, since the fibrous body 4 communicates between the first side surface and the second side surface, it has more moisture permeability.

[0031] In addition, the resin foams 3 arranged adjacent to each other have different hardnesses. Therefore, the resin foams 3 can enhance the usability more by having an appropriate hardness according to the user's body part. As shown in FIG. 1 and the like, there are cases where the resin foams 3 are arranged along the longitudinal direction and cases where they are arranged along the width direction as shown in FIG. 2 and the like. Further, as shown in FIG. 6 and the like, there are cases where the resin foams 3 are formed along the longitudinal direction and the width direction, and cases (not shown) where the resin foams 3 are arranged so as to intersect at a predetermined angle with respect to the longitudinal direction and the width direction, each having a unique effect. Details will be described for each embodiment.

[0032] <<Contents specific to each embodiment according to the first aspect>> <Contents common to the mattress 1a of the first embodiment to the mattress 1e of the fifth embodiment and the mattress 1g of the seventh embodiment to the mattress 1j of the ninth embodiment> Next, the contents specific to each embodiment of the mattress 1 according to the first aspect of the present invention will be described. First, the contents common to the mattress 1a of the first embodiment to the mattress 1e of the fifth embodiment and the mattress 1g of the seventh embodiment to the mattress 1j of the ninth embodiment will be described. The resin foam 3 is separated into five or more odd-numbered parts along the longitudinal direction, or / and the width direction, and among the plurality of parts arranged in the width direction, the central part and the both-end parts have the same hardness. Hereinafter, the case where the resin foam 3 is separated along the longitudinal direction, the case where it is separated along the width direction, and the case where it is further separated along the longitudinal direction and the width direction will be described separately.

[0033] In the first example, the resin foam 3 is separated into five or more odd-numbered portions along the longitudinal direction. Among the plurality of portions arranged in the width direction, the central portion and the end portions have the same hardness. In the example shown in FIG. 1 and the like, the resin foam 3 is separated and arranged in five rows along the longitudinal direction. In this case, the central row and the end rows of the resin foam 3 have the same hardness. Although the resin foam 3 is shown as an example of five rows, it may be an odd number of rows such as seven rows, nine rows, or eleven rows or more. Further, the resin foam 3 does not necessarily have to be continuous along the longitudinal direction. Details will be described later with reference to FIG. 15. The hardness of the central portion and the end portions is, for example, from 150 N to 250 N. Note that the hardness of the central portion and the end portions does not necessarily have to be exactly the same, and it may be within the range regarded as equivalent by common technical knowledge. Note that the value of the hardness is an example.

[0034] In the second example, the resin foam 3 is separated into five or more odd-numbered portions along the width direction. Among the plurality of portions arranged in the longitudinal direction, the central portion and the end portions have the same hardness. In the example shown in FIG. 2 and the like, the resin foam 3 is separated and formed into five rows along the width direction. In this case, the central row and the end rows of the resin foam 3 have the same hardness. Similar to the case where the resin foam 3 is arranged along the longitudinal direction, in addition to five rows, it may be an odd number of rows such as seven rows, nine rows, or eleven rows or more. Further, the resin foam 3 does not necessarily have to be continuous along the width direction. Details will be described together when explaining with reference to FIG. 15.

[0035] In the third example, the resin foam 3 is separated into five or more odd-numbered portions in each of the longitudinal direction and the width direction. Among the plurality of portions, the central portion and the end portions have the same hardness. In the example shown in FIG. 6 and the like, the resin foam 3 is separated and arranged in five rows in each of the longitudinal direction and the width direction. There are cases where the hardness of the resin foam 3 is set with the direction along the longitudinal direction as the reference of the row direction and cases where the direction along the width direction is used as the reference of the row direction. Details will be described for each embodiment.

[0036] Also, in the examples from the first example to the third example, in the resin foam 3, the hardness of the both-end portions and the central portion is higher than that of the other portions disposed adjacent thereto. An example of the hardness is formed by the high-hardness body 3a, and the both-end portions and the central portion with high hardness are from 150 N to 250 N. The portion with low hardness is formed by the low-hardness body 3b and is from 90 N to 140 N. The hardness value is an example, and there only needs to be a difference between the hardness of the high-hardness body 3a and the hardness of the low-hardness body 3b. In the example shown in FIG. 3 and the like, the resin foam 3 is arranged in five columns, and the first-column resin foam 31, the third-column resin foam 33, and the fifth-column resin foam 35 are the high-hardness body 3a, and the second-column resin foam 32 and the fourth-column resin foam 34 are the low-hardness body 3b.

[0037] <Common effects of the mattress 1a of the first embodiment to the mattress 1e of the fifth embodiment and the mattress 1g of the seventh embodiment to the mattress 1j of the ninth embodiment> According to the common content of the mattress 1a of the first embodiment to the mattress 1e of the fifth embodiment and the mattress 1g of the seventh embodiment to the mattress 1j of the ninth embodiment described above, the following effects are achieved. As shown in FIG. 3 and the like, the resin foams 3 arranged in five or more odd-numbered portions have different hardnesses from each other between adjacent resin foams 3, and the central portion and the both-end portions have equal hardness. Therefore, when the resin foam 3 is along the longitudinal direction, the user can turn over to both sides in the width direction in a similar feeling centering around the central column in the width direction. When the resin foam 3 is along the width direction, the usability can be enhanced by setting the hardness according to the site in the body length direction.

[0038] Also, as shown in FIG. 3 and the like, the both-end portions and the central portion of the resin foam 3 have higher hardness than the other portions. Therefore, when the resin foam 3 is arranged in odd-numbered portions along the longitudinal direction, it can be easily turned over to lie on the side from the center in the width direction toward the end, and can be easily turned over again to lie on the back toward the center, so the turn-over property is further improved. Also, when the resin foam 3 is arranged in odd-numbered portions along the width direction, it is possible to suppress the depression even when sitting upright at both end portions in the longitudinal direction. Furthermore, the central portion in the body length direction can be supported.

[0039] <Contents of the mattress 1a of the first embodiment according to the first aspect> Next, the mattress 1a of the first embodiment according to the first aspect will be described. Parts that overlap with the common contents and effects already described will be omitted from the description. The same applies to the following other embodiments. Referring to FIGS. 1, 3, and 4, the mattress 1a of the first embodiment will be described. As shown in FIG. 1, five columns of resin foams 3 are formed along the longitudinal direction in the mattress 1a. The fibrous bodies 4 are intermittently formed in a plurality of columns at the boundary portions 5.

[0040] As shown in FIGS. 3 and 4, the fibrous bodies 4 shown in the cross-section I-I can be applied in various forms. In the example shown in FIG. 3(a), the fibrous bodies 4 are formed so as to be exposed only on the first side in the thickness direction. In the portion where the fibrous bodies 4 are not formed, the adjacent resin foams 3 are directly adhered to each other at the boundary portion 5. The resin foams 3 are formed in order of the first row resin foam 31 which is a high hardness body 3a, the second row resin foam 32 which is a low hardness body 3b from the left in the figure, and are formed up to the fifth row resin foam 35. The high hardness body 3a and the low hardness body 3b are arranged alternately. In the example shown in FIG. 3(b), the fibrous bodies 4 are formed on both the first side and the second side in the thickness direction, and the first side and the second side are in a separated form. FIG. 3(c) is a form in which the fibrous bodies 4 are formed on both the first side and the second side in the thickness direction as already described, and the surface on the first side and the surface on the second side communicate with each other. The hardness of the resin foam 3 in FIGS. 3(b) and 3(c) is set in the same manner as in FIG. 3(a).

[0041] <Contents of the mattress 1b of the second embodiment according to the first aspect> Next, the mattress 1b of the second embodiment according to the first aspect will be described. As shown in FIG. 2, five columns of resin foams 3 are formed along the width direction of the mattress 1b. The fibrous bodies 4 are intermittently formed in a plurality of columns at the boundary portions 5. The cross-section II-II in FIG. 2 is as shown in FIG. 3, and the resin foam 3, the boundary portion 5, and the fibrous body 4 are in the same form as the mattress 1a. In practice, since the overall length dimensions are different in the longitudinal direction and the width direction, the lengths in the left-right direction shown in the figure from the first-row resin foam 31 to the fifth-row resin foam 35 are different. The same applies to FIGS. 7 to 9, FIGS. 13, 14, and FIGS. 19 to 21 described later.

[0042] <Effects of the mattress 1a of the first embodiment and the mattress 1b of the second embodiment according to the first aspect> According to the mattress 1a of the first embodiment and the mattress 1b of the second embodiment described above, since the fibrous bodies 4 are intermittently formed in a plurality of columns along the longitudinal direction or the width direction, they have hygroscopicity and / or moisture permeability over a wide range. Also, at the boundary portion 5, since there are portions where adjacent resin foams 3 are directly adhered to each other, the adhesion strength of the mattress 1a and the mattress 1b is increased.

[0043] <Contents of the mattress 1c of the third embodiment according to the first aspect> Next, with reference to FIGS. 4 and 7 to 9, the mattress 1c of the third embodiment will be described. As shown in FIG. 4, the resin foam 3 and the fibrous body 4 of the mattress 1c are continuously arranged from one end to the other end in the longitudinal direction. The resin foam 3 and the fibrous body 4 are alternately arranged and adhered. The resin foam 3 is arranged in five columns along the longitudinal direction. The fibrous bodies 4 are formed at all of the boundary portions 5 and are arranged in four columns along the longitudinal direction.

[0044] Referring to FIGS. 7 to 9, the cross-section III-III in FIG. 4 will be described. Various cross-sectional shapes are applicable. As already described, in the resin foam 3, the high-hardness body 3a and the low-hardness body 3b are alternately formed from the first-row resin foam 31 to the fifth-row resin foam 35 with the fibrous body 4 at the boundary portion 5 interposed therebetween. The example shown in FIG. 7 is a case where both the first side and the second side in the thickness direction are flat. The fibrous body 4 is formed to communicate from the surface on the first side to the surface on the second side in the thickness direction. The forms from the first-row resin foam 31 to the fifth-row resin foam 35 are the same as those in FIG. 3(c).

[0045] In the example shown in FIG. 8, the first side in the thickness direction has an uneven shape. Although not shown in FIG. 4, the uneven shape is formed by ridges and grooves. The uneven shapes from the first-row resin foam 31 to the fifth-row resin foam 35 are all of the same shape. The high-hardness body 3a and the low-hardness body 3b are set in hardness at the material level. The formation of the uneven shape is, for example, as shown in FIG. 7, by performing profile processing in a state where the resin foam 3 and the fibrous body 4 are pre-bonded at the boundary portion 5.

[0046] In the example shown in FIG. 8, the cross-sectional shapes of the four rows of fibrous bodies 4 are different from each other. Between the first-row resin foam 31 and the second-row resin foam 32, it is bonded to the middle part of the slope of the convex part and formed up to the apex height of the convex part on the first side in the thickness direction. Between the second-row resin foam 32 and the third-row resin foam 33, it is bonded to the middle part of the slope of the convex part, and the first side is formed to a height recessed from the apex of the convex part. Between the third-row resin foam 33 and the fourth-row resin foam 34, it is formed up to the height of the bottom of the concave part. Between the fourth-row resin foam 34 and the fifth-row resin foam 35, it is bonded at the apex part of the convex part and formed up to the apex height of the convex part. Although the forms of the fibrous body 4 are exemplified as different forms for each of the four rows, they may all be of the same form, or a plurality of them may be the same.

[0047] In the example shown in Fig. 9, the first side in the thickness direction has an uneven shape. Different from the example in Fig. 8, the uneven shapes of the first sides in the adjacent resin foams 3 are different. The difference between the high-hardness body 3a and the low-hardness body 3b is formed by the difference in the uneven shape, rather than the hardness difference at the material level. The convex shapes of the first-row resin foam 31, the third-row resin foam 33, and the fifth-row resin foam 35 are formed with wide skirts to increase the hardness. On the contrary, the second-row resin foam 32 and the fourth-row resin foam 34 are formed with narrow skirts to lower the hardness. In addition to the difference in the convex shape, a hardness difference may be provided at the material level.

[0048] In the example shown in Fig. 9, the four rows of fibrous bodies 4 are formed as part of the convex portions between the first-row resin foam 31 and the second-row resin foam 32, and between the fourth-row resin foam 34 and the fifth-row resin foam 35. They are formed as part of the concave portions between the second-row resin foam 32 and the third-row resin foam 33, and between the third-row resin foam 33 and the fourth-row resin foam 34. The forms of the fibrous bodies 4 in all four rows may be different, or all may be the same, or a plurality of them may be the same.

[0049] <Contents of the mattress 1d of the fourth embodiment according to the first aspect> Next, with reference to Figs. 5, 7 to 9, the mattress 1d of the fourth embodiment will be described. As shown in Fig. 5, in the mattress 1d, the resin foams 3 and the fibrous bodies 4 are continuously arranged from one end in the width direction to the other end. The resin foams 3 and the fibrous bodies 4 are arranged alternately and adhered. The resin foams 3 are arranged in five rows along the width direction. The fibrous bodies 4 are formed at all the boundary portions 5 and are arranged in four rows along the width direction. The cross-section IV-IV in Fig. 5 is the same as Figs. 7 to 9 described in the mattress 1c.

[0050] <Effects of the mattress 1c of the third embodiment and the mattress 1d of the fourth embodiment according to the first aspect> According to the mattress 1c of the third embodiment and the mattress 1d of the fourth embodiment described above, the following effects can be achieved. In the mattresses 1c and 1d, the resin foam 3 and the fibrous body 4 are continuously arranged from one end to the other end in either the longitudinal direction or the width direction, and the resin foam 3 and the fibrous body 4 are alternately arranged and adhered. The fibrous body 4 communicates with the first-side surface and the second-side surface in the thickness direction, and is further exposed on both surfaces and formed uniformly and over a wide range. Therefore, it has hygroscopicity and / or moisture permeability over a wider range. Also, as shown in FIG. 9, by forming different uneven shapes, a hardness difference between the high-hardness body 3a and the low-hardness body 3b is formed, so that a hardness difference can be provided using the same kind of material.

[0051] <Contents of the mattress 1e of the fifth embodiment according to the first aspect> Next, the mattress 1e of the fifth embodiment will be described with reference to FIGS. 6 to 9. In the mattress 1e, the resin foam 3 and the fibrous body 4 are continuously arranged from one end to the other end in either the longitudinal direction or the width direction. The resin foam 3 and the fibrous body 4 are alternately arranged. The cross-section V-V in FIG. 6 is a cross-sectional view when the longitudinal direction of the resin foam 3 is taken as the column reference. The resin foam 3 has the first-row resin foam 31 to the fifth-row resin foam 35 arranged along the longitudinal direction. In this case, the resin foams 3 arranged adjacent to each other along the longitudinal direction have different hardnesses. Each row of resin foam 3 has the same hardness from one end to the other end in the longitudinal direction. Note that, for simplicity, FIG. 6 shows the reference numerals from the first-row resin foam 31 to the fifth-row resin foam 35 when the longitudinal direction is taken as the reference.

[0052] The cross-section VI-VI is a cross-sectional view when the width direction of the resin foam 3 is taken as the column reference. In this case, the resin foams 3 arranged adjacent to each other along the width direction have different hardnesses. The resin foam 3 has the first-row resin foam 31 to the fifth-row resin foam 35 arranged along the width direction. Each row of resin foam 3 has the same hardness from one end to the other end in the width direction. The configurations of the resin foam 3 and the fibrous body 4 shown in FIGS. 7 to 9 have already been described as above and are the same as those of the mattress 1c.

[0053] Furthermore, the mattress 1e of the fifth embodiment can also have the following configuration. Although the resin foam 3 has been described as being arranged along the longitudinal direction and the width direction, the resin foam 3 may be individually separated without forming rows by the boundary portion 5. That is, the adjacent resin foams 3 may have different hardnesses regardless of the longitudinal direction and the width direction. Alternatively, not all of the adjacent resin foams 3 have different hardnesses. For example, a plurality of adjacent resin foams 3 that are continuously adjacent in one direction can be taken as one unit, and various settings such as different hardnesses for each unit are possible.

[0054] <Contents of the mattress 1f of the sixth embodiment according to the first aspect> Next, the mattress 1f of the sixth embodiment will be described. Although not shown in the drawings, the resin foams 3 are arranged so as to intersect at a predetermined angle with respect to the longitudinal direction and the width direction. Further, they are arranged continuously from one end to the other end. The resin foams 3 and the fibrous bodies 4 are arranged alternately.

[0055] Furthermore, the mattress 1f of the sixth embodiment can also have the following configuration. Although the resin foam 3 has been described as being arranged so as to intersect at a predetermined angle with respect to the longitudinal direction and the width direction, the resin foam 3 may be individually separated without forming rows by the boundary portion 5. That is, the adjacent resin foams 3 may have different hardnesses from each other. Alternatively, not all of the adjacent resin foams 3 have different hardnesses. For example, a plurality of adjacent resin foams 3 that are continuously adjacent in one direction can be taken as one unit, and various settings such as different hardnesses for each unit are possible.

[0056] <Effects of the mattress 1e of the fifth embodiment and the mattress 1f of the sixth embodiment according to the first aspect> According to the mattress 1e of the fifth embodiment and the mattress 1f of the sixth embodiment described above, the following effects can be achieved. In both the mattress 1e and the mattress 1f, the fibrous body 4 is formed in a lattice shape and communicates with the first side surface and the second side surface in the thickness direction. Therefore, the area where the fibrous body 4 is exposed becomes wider, and it has better moisture absorption and moisture release properties. In addition, the hardness of each resin foam 3 can be set in various units not limited to the column direction, so the degree of freedom in setting the hardness is high according to the intended use.

[0057] <Contents of the mattress 1g of the seventh embodiment according to the first aspect> Next, with reference to FIGS. 10, 13, and 14, the mattress 1g of the seventh embodiment will be described. The mattress 1g is different from the mattress 1c already described in the form of the fibrous body 4, and the rest is the same. That is, the fibrous body 4 is formed by being exposed on the first side surface and / or the second side surface in the thickness direction, but the first side and the second side are separated. In the example shown in FIG. 13, the first side and the second side in the thickness direction are formed as flat surfaces. Between the first row resin foam 31 and the second row resin foam 32, the fibrous body 4 is formed by being exposed on the first side surface and the second side surface in the thickness direction, but the first side and the second side of the fibrous body 4 are separated. Between the second row resin foam 32 and the third row resin foam 33, the fibrous body 4 is formed by being exposed only on the first side surface. Between the third row resin foam 33 and the fourth row resin foam 34, the fibrous body 4 is formed by being exposed only on the second side surface. Between the fourth row resin foam 34 and the fifth row resin foam 35, it is the same as between the first row resin foam 31 and the second row resin foam 32.

[0058] In the example shown in FIG. 14, the first side in the thickness direction is formed by an uneven shape. It is the same as the uneven shape described with reference to FIG. 9. The fibrous body 4 is exposed on both the first side surface and the second side surface in the thickness direction as in FIG. 13, and there are locations where the first side and the second side are separated and locations where it is exposed only on either the first side or the second side. Note that, as described with reference to FIG. 9, the uneven shape may have a hardness difference as different shapes between adjacent resin foams 3.

[0059] Note that the form of the fibrous body 4 is just an example. Although an example where all of the fibrous body 4 separates between the first side and the second side in the thickness direction has been shown, a part of it may communicate with the surface of the first side and the surface of the second side. Also, although an example where the fibrous body 4 is exposed on both the surface of the first side and the surface of the second side in the thickness direction has been shown, it may be exposed only on either one of them. The same applies to the mattress 1h of the eighth embodiment to the mattress 1k of the tenth embodiment described below.

[0060] <Contents of the mattress 1h of the eighth embodiment according to the first aspect> Next, with reference to FIGS. 11, 13, and 14, the mattress 1h of the eighth embodiment will be described. The mattress 1h is different from the mattress 1d already described in the form of the fibrous body 4, and the rest is the same. The cross-section X-X showing the form of the fibrous body 4 is the same as that of the mattress 1g described with reference to FIGS. 13 and 14.

[0061] <Effects of the mattress 1g of the seventh embodiment and the mattress 1h of the eighth embodiment according to the first aspect> According to the mattress 1g of the seventh embodiment and the mattress 1h of the eighth embodiment described above, in addition to the effects of the mattress 1c and the mattress 1d, the following effects are achieved. In both the mattress 1g and the mattress 1h, the fibrous body 4 is exposed on the surface of the first side or the second side in the thickness direction, and the first side and the second side are separated. Therefore, a portion where the adjacent resin foams 3 are directly adhered to each other is formed at the boundary portion 5. The adjacent resin foams 3 are, for example, urethane foams, and the same kind of materials have good adhesiveness. At least a part of the boundary portion 5 in the thickness direction is where the adjacent resin foams 3 are adhered to each other. Therefore, by partially forming the fibrous body 4 at the boundary portion 5, the hygroscopicity and / or the moisture permeability can be enhanced, and by partially adhering the resin foams 3 to each other, the adhesive strength can be enhanced.

[0062] <Contents of the mattress 1j of the ninth embodiment according to the first aspect> Next, with reference to FIGS. 12 to 14, the mattress 1j of the ninth embodiment will be described. The mattress 1j is different from the mattress 1e already described in the form of the fibrous body 4, and the others are the same. That is, as shown in FIG. 12, among the rows of the boundary portions 5 along the longitudinal direction and the rows of the boundary portions 5 along the width direction, there are rows where the fibrous body 4 is not exposed on the first side and the second side in the thickness direction. The cross-sections XI-XI and XII-XII in FIG. 12 are as shown in FIG. 13 or FIG. 14 already described.

[0063] <Contents of the mattress 1k of the tenth embodiment according to the first aspect> Next, the mattress 1k of the tenth embodiment will be described. The mattress 1k is different from the mattress 1f already described in the form of the fibrous body 4, and the others are the same. That is, among the boundary portions 5 formed by intersecting at a predetermined angle with respect to the longitudinal direction and the width direction, there are rows where the fibrous body 4 is not exposed on the first side and the second side in the thickness direction.

[0064] <Effects of the mattress 1j of the ninth embodiment and the mattress 1k of the tenth embodiment according to the first aspect> According to the mattress 1j of the ninth embodiment and the mattress 1k of the tenth embodiment described above, in addition to the effects of the mattress 1e and the mattress 1f, the following effects are achieved. In both the mattress 1j and the mattress 1k, the fibrous body 4 is formed in a lattice shape, exposed on the surface of the first side or the second side in the thickness direction, and the first side and the second side are separated. Therefore, the area where the fibrous body 4 is exposed becomes wider, and it has more hygroscopicity and moisture permeability. Further, a portion where the adjacent resin foams 3 are directly adhered is formed at the boundary portion 5. Therefore, similar to the mattress 1g and the mattress 1h, the adhesive strength can be increased by partially adhering the resin foams 3 to each other at the boundary portion 5.

[0065] <Contents of the mattress 1m of the eleventh embodiment according to the first aspect> Next, referring to FIGS. 15 and 16, the mattress 1m of the eleventh embodiment will be described. The mattress 1m is divided into a plurality of regions by a dividing line 11 perpendicular to the direction in which the resin foam 3 extends, and the resin foam 3 and the fibrous body 4 are arranged discontinuously with the dividing line 11 as a boundary. In the example shown in FIG. 15, the resin foams 3 are arranged along the longitudinal direction, and the dividing line 11 is formed along the width direction. Specifically, the mattress 1m is separated into a plurality of pieces by the dividing line 11, and they may be arranged side by side in the longitudinal direction during use. Alternatively, the dividing line 11 is a folding line, and it may be folded at the dividing line 11 and stacked, for example, in four layers.

[0066] As shown in FIG. 15, at the dividing line 11, the fibrous body 4 contacts the resin foam 3. That is, in the longitudinal direction, the resin foam 3 and the fibrous body 4 are staggered and discontinuous. In the example shown in FIG. 16(a), in the cross-section XV-XV of FIG. 15, the first side surface and the second side surface are formed in a plane, and the fibrous body 4 communicates the first side surface and the second side surface in the thickness direction. In the cross-section XV-XV, the resin foam 3 forms six rows, and in order from the left in the figure, a high-hardness body 3a and a low-hardness body 3b are alternately formed with the fibrous body 4 interposed therebetween. As in the example shown in FIG. 16(b), in the cross-section XVI-XVI of FIG. 15, the resin foam 3 forms five rows, and in order from the left in the figure, a high-hardness body 3a and a low-hardness body 3b are alternately formed with the fibrous body 4 interposed therebetween.

[0067] Although not shown, as described with reference to FIGS. 8 or 9, the first side in the thickness direction of the mattress 1m may have an uneven shape. Also, although an example in which the fibrous body 4 communicates the first side surface and the second side surface in the thickness direction has been shown, as already described, it may be exposed on at least one of the first side surface or the second side surface, and the first side and the second side may be separated. Further, although not shown, the resin foam 3 and the fibrous body 4 may be formed along the width direction, and the resin foam 3 and the fibrous body 4 may be staggered and discontinuous at the dividing line 11.

[0068] <Effect of the mattress 1m of the eleventh embodiment according to the first aspect> According to the mattress 1m of the eleventh embodiment described above, the following effects can be achieved. Since the resin foam 3 and the fibrous body 4 are arranged discontinuously with the division line 11 as the boundary, the positions of the resin foam 3 and the fibrous body 4 can be changed according to the user's body part. Further, since the resin foam 3 can have the high-hardness body 3a and the low-hardness body 3b arranged alternately along the longitudinal direction, it is possible to suppress problems such as partial indentation during use or after long-term use. The same applies when they can be arranged alternately along the width direction.

[0069] <<Description of the mattress 2 according to the second aspect>> Next, the mattress 2 according to the second aspect of the present invention will be described. The conventional example taking Patent Document 1 as an example has the following problems. In the conventional example described in Patent Document 1, a hardness gradient is formed in which the hardness is high at the central portion in the width direction and gradually decreases from the central portion toward the ends. Therefore, the hardness at the ends in the width direction is low, and although it is possible to turn over from the central portion toward the ends, it is difficult to turn over again toward the central portion. That is, when turning over from the central portion toward the ends and lying on the side, it is assumed that the body sinks at the ends and it is difficult to turn over again toward the center and lie on the back. Further, there is a problem that it sinks in the case of sitting upright. Further, when the technique described in Patent Document 1 is applied in the longitudinal direction, the hardness is high at the central portion in the height direction, and the hardness is low at the head and foot portions. Then, there is a problem that the head, which is originally heavy, sinks and the feet drop. On the other hand, the object of the invention according to the second aspect is to provide a mattress 2 that enhances the usability by setting an appropriate hardness according to the user's body part and further improves the turn-over property.

[0070] The mattress 2 includes the mattress 2a of the first embodiment and the mattress 2b of the second embodiment. This will be described with reference to FIGS. 17 to 21. The mattress 2 has a predetermined thickness in the thickness direction and is formed in a substantially rectangular parallelepiped shape that extends in the longitudinal direction and the width direction. The mattress 2 includes a resin foam 3. The resin foam 3 is separated into a plurality of parts, a boundary portion 5 is formed between adjacent resin foams 3, and they are adhered to each other at the boundary portion 5. The adjacent resin foams 3 have different hardnesses from each other.

[0071] <<Effects of the mattress 2 according to the second aspect>> According to the common content of the mattress 2 described above, the following effects can be achieved. In the mattress 2, the adjacent resin foams 3 have different hardnesses from each other. Therefore, the resin foam 3 can improve the usability by setting an appropriate hardness according to the user's body part.

[0072] <Description of the mattress 2a of the first embodiment> The mattress 2a of the first embodiment according to the second aspect will be described. In the mattress 2a of the first embodiment, the resin foam 3 is separated into five or more odd-numbered parts along the longitudinal direction. In the example shown in FIG. 17, the resin foams 3 are arranged in five rows. As shown in FIGS. 20 and 21, among the plurality of parts arranged in the width direction, the central part and the both-end parts have the same hardness.

[0073] As shown in FIGS. 20 and 21, which are cross-sectional views of cross-section XVII-XVII in FIG. 17, the both-end parts and the central part are harder than the other parts arranged adjacent to them. Specifically, the first-row resin foam 31, the third-row resin foam 33, and the fifth-row resin foam 35 are high-hardness bodies 3a, and the second-row resin foam 32 and the fourth-row resin foam 34 are low-hardness bodies 3b. The examples of hardness are the same as the values described for the mattress 1 according to the first aspect.

[0074] As shown in FIGS. 20 and 21, the first side in the thickness direction is formed with a concavo-convex shape. In the example shown in FIG. 20, the concavo-convex shape is the same in all of the first to fifth resin foams 31 to 35, and although not shown in FIG. 17, it is formed of ridges and grooves. The high-hardness body 3a and the low-hardness body 3b are set to have high and low hardnesses at the material level, respectively.

[0075] In the example shown in FIG. 21, the concavo-convex shapes of the first resin foam 31, the third resin foam 33, and the fifth resin foam 35 are different from the concavo-convex shapes of the second resin foam 32 and the fourth resin foam 34. The difference in the concavo-convex shape is the same as that compared with reference to FIGS. 8 and 9 already. Due to the difference in the concavo-convex shape, the high-hardness body 3a and the low-hardness body 3b are formed. In this case, the material of the resin foam 3 uses urethane foam as an example, but the same material may be used for all of the first to fifth resin foams 31 to 35, or materials having different hardnesses may be used according to the high-hardness body 3a and the low-hardness body 3b at the material level. Note that, as described with reference to FIG. 7 and the like for the mattress 1 according to the first aspect, the first side and the second side in the thickness direction may be formed as planes.

[0076] <Effect of the mattress 2a of the first embodiment> According to the mattress 2a of the first embodiment described above, the following effects are obtained. The resin foams 3 arranged in an odd number of columns of five columns or more have different hardnesses from each other, and the central column and the columns at both ends in the width direction have the same hardness. Therefore, the user can turn over to both sides with the same feeling centering on the central column in the width direction.

[0077] Also, the resin foams 3 arranged in the center in the width direction and the resin foams 3 arranged at both ends in the width direction are formed with high hardness, and the adjacent resin foams 3 are formed with lower hardness than the resin foam 3. Therefore, it is easy to turn over so as to lie on the side from the center in the width direction toward the end, and it is easy to turn over so as to lie on the back again toward the center, so that the turn-over property is further improved.

[0078] <Explanation of the mattress 2b of the second embodiment> Next, the mattress 2b of the second embodiment will be described. The resin foam 3 of the mattress 2b is separated into five or more odd-numbered portions along the width direction. In the example shown in FIG. 18, the resin foams 3 are arranged in five rows. As shown in FIGS. 20 and 21, among the plurality of portions arranged in the width direction, the central portion and the end portions have the same hardness. FIGS. 20 and 21, which are cross-sectional views of cross-section XVIII-XVIII in FIG. 18, are the same as the content described for the mattress 2a.

[0079] <Effect of the mattress 2b of the second embodiment> According to the mattress 2b of the second embodiment described above, the following effects are obtained. The resin foams 3 arranged in five or more odd-numbered rows have different hardnesses from each other, and the central row and the end rows in the longitudinal direction have the same hardness. Therefore, the user can use it with a similar feeling of contact in the portions corresponding to the head, waist, and legs of the body.

[0080] Also, the resin foams 3 arranged in the center in the longitudinal direction and the resin foams 3 arranged at both ends in the longitudinal direction are formed with high hardness, and the adjacent resin foams 3 are formed with lower hardness than the resin foams 3. Therefore, since the hardness of the central portion and the end portions in the longitudinal direction is high, the head, waist, and legs can be supported. Also, it is possible to sit upright at both ends in the longitudinal direction.

Description of reference numerals

[0081] 1, 1a, 1b, 1c, 1d, 1e, 1f, 1g, 1h, 1j, 1k, 1m, 2, 2a, 2b Mattresses 3 Resin foam 4 Fiber body 5 Boundary portion

Claims

1. A mattress formed in a substantially rectangular parallelepiped shape having a predetermined thickness in the thickness direction and extending in the longitudinal and width directions, The present invention includes a resin foam and a fibrous body, The resin foam is separated into a plurality of portions, and boundaries are formed between adjacent resin foams, The fibrous body is positioned at at least a portion of the boundary portion and is adhered to the resin foam body in a state where it is exposed on at least one surface in the thickness direction.

2. The mattress according to claim 1 , wherein the fibrous body is exposed on both surfaces in the thickness direction and is connected from one surface to the other surface.

3. The mattress according to claim 1 , wherein adjacently disposed resin foams have different hardnesses.

4. The resin foam is divided into five or more odd-numbered portions along the longitudinal direction, The mattress according to claim 3 , wherein among the multiple sections aligned in the width direction, the central section and both end sections have the same hardness.

5. 5. The mattress of claim 4, wherein the end portions and the central portion have a harderness than the other portions adjacent thereto.

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