Mattress

Abstract

To provide a mattress with good quality and comfortable to use by circulating an air current all over the inside thereof.SOLUTION: A mattress comprises a breathable elastic layer and a non-breathable covering layer. The covering layer is a film integrated with the elastic layer and covering a surface of the elastic layer, and includes a ventilation part not covered with the covering layer. The mattress can thus exhaust, by a ventilation mechanism, the air supplied to the elastic layer from the ventilation part, or the air supplied to the ventilation part from the elastic layer.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mattress.

Background Art

[0002] Currently, mattresses that comfortably support the body have been developed.

[0003] For example, Patent Document 1 describes an air-conditioned bed capable of sending air into the surface of a mattress (FIG. 1 etc.).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the above-described mattress, in order to efficiently send air into the surface of the mattress, it is necessary to combine non-breathable members to form a flow path. Then, since breathability cannot be ensured in parts other than the flow path, ventilation inside the mattress may not be sufficiently performed, or a comfortable sleep or usability may not be obtained.

[0006] Therefore, an object of the present invention is to provide a mattress in which an air flow spreads inside and which can be used with good quality and comfort.

Means for Solving the Problems

[0007] This application includes a plurality of means for solving at least part of the above problems. For example, they are as follows. A mattress according to one aspect of the present invention for solving the above problems is a mattress including a breathable elastic layer and an airtight coating layer, wherein the coating layer is a film that is integrated with the elastic layer to cover the surface, and includes a ventilation portion that is not covered by the coating layer, and an air ventilation mechanism can exhaust the air supplied to the elastic layer from the ventilation portion, or exhaust the air supplied to the ventilation portion from the elastic layer.

[0008] The air ventilation mechanism may suck the air supplied to the elastic layer from another position.

[0009] The coating layer may be formed by heat-treating the surface of the elastic layer into a film shape.

[0010] The ventilation portion may be a portion where the elastic layer is not partially formed into a film shape.

[0011] The ventilation portion may be a portion where the coating layer is partially removed.

[0012] The ventilation portion may be a cut surface where the elastic layer is cut. The ventilation portion may be a surface with irregularities cut by profiling the elastic layer.

[0013] The coating layer may be formed by heat-treating a coating material covering the surface of the elastic layer into a film shape.

[0014] The coating layer may be formed by forming a film with a liquid coating material on the surface of the elastic layer.

[0015] The elastic layer includes a main elastic layer and a sub-elastic layer having higher breathability than the main elastic layer, and the air ventilation mechanism may be connected to the sub-elastic layer.

[0016] The ventilation mechanism may include at least any one of an air purification unit, a temperature control unit, a humidity control unit, and a heat exchanger.

[0017] A plurality of the mattresses may be connected to each other in the lateral direction so as to be ventilable.

[0018] In the ventilation part formed in a corrugated shape by the profile processing, a part from above the convex part may have a higher hardness than other parts.

[0019] In the ventilation part formed in a corrugated shape by the profile processing, a valve that opens and closes depending on the presence or absence of a load may be provided at the bottom of the concave part.

[0020] Also, another aspect of the present invention is A method for manufacturing a mattress, comprising a breathable elastic layer, an airtight coating layer covering the elastic layer, and a ventilation part not covered by the coating layer, wherein air supplied to the elastic layer is exhausted from the ventilation part by a ventilation mechanism, or air supplied to the ventilation part is exhausted from the elastic layer, a) By subjecting the surface of the elastic layer to heat treatment to form a film, i) By subjecting a coating material covering the surface of the elastic layer to heat treatment to form a film, or iii) By forming a film on the surface of the elastic layer with a liquid coating material, having a step of forming the coating layer that integrally covers the surface on the elastic layer is a method for manufacturing a mattress.

[0021] The method may have a step of forming the ventilation part by cutting or removing the coating layer.

[0022] The elastic layer includes a main elastic layer and a sub-elastic layer having higher breathability than the main elastic layer and to which the ventilation mechanism is connected, and the method may have a step of cutting the main elastic layer by profile processing for a member in which the main elastic layer and the sub-elastic layer are laminated.

Advantages of the Invention

[0023] According to the present invention, it is possible to provide a mattress in which air flow spreads internally and which can be used in good quality and comfortably.

[0024] Problems, configurations, and effects other than those described above will be clarified by the description of the following embodiments.

Brief Description of the Drawings

[0025]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Modes for Carrying Out the Invention

[0026] Hereinafter, examples of embodiments of the present invention will be described with reference to the drawings. Regarding the components common to the following embodiments, the same reference numerals as those used above may be given, and the description may be omitted. Also, when referring to the shape, positional relationship, etc. of components, etc., unless otherwise specified or considered not to be so in principle, those substantially approximate or similar to the shape, etc. are included.

[0027] The present invention relates to a mattress used by laying it on a bed, sofa, chair, etc. to support the body. In other words, the mattress according to the present invention is what is called a so-called mattress laid on a bed, a so-called cushion laid on a sofa, and a so-called zabuton laid on a chair, tatami, etc., depending on the object to be laid. The mattress according to the present invention can also be used as a pillow.

[0028] The mattress according to one aspect of the present invention includes a main elastic layer, a coating layer, and a ventilation part, and further includes a ventilation mechanism for ventilating inside the mattress. The coating layer is an airtight film that covers the main elastic layer, and by providing a ventilation part 14 that is not covered by the coating layer, air can be passed through the main elastic layer.

[0029] <Embodiment 1> FIG. 1 is a schematic view showing an example of a mattress according to Embodiment 1. The mattress 1 of this embodiment sends air into the breathable main elastic layer 11 covered with the airtight coating layer 12 by the ventilation mechanism 19 to generate an air current to the ventilation part 14 provided on the upper surface (hereinafter referred to as the pressing surface) pressed by the user's body. Hereinafter, it will be specifically described. The broken line F in FIG. 1 is a cross-sectional line provided for convenience to show the inside of the mattress 1.

[0030] The main elastic layer 11 is a layer that forms the interior of the mattress 1. It is made of an elastic body that has breathability and appropriate thickness and elasticity. The thickness of the main elastic layer 11 is not particularly limited and can be configured to the thickness required for a mattress as a bedding. As an example, for the main elastic layer 11, an elastic body using a synthetic resin or the like having breathability and thermoplasticity or thermosetting properties, such as a foam material like polyethylene foam, rubber sponge, urethane foam, or a cushion material of resin fibers, is used.

[0031] The covering layer 12 is the surface layer of the main elastic layer 11 and covers the whole except for the ventilation part 14 and the air supply and exhaust ports 15. The covering layer 12 is formed by heat-treating the surface of the main elastic layer 11 as shown in FIG. 2, causing the surface of the main elastic layer 11 itself to melt and integrate into a non-breathable film-like coating. Therefore, when pressed, the covering layer 12 deforms following the deformation of the main elastic layer 11, and no gap is formed between the main elastic layer 11 and the covering layer 12. Here, although the air supply and exhaust ports 15 are formed in advance, they may be formed later. The thickness of the covering layer 12 may be any degree considering comfort as long as there is no gas leakage. For example, it is 0.5 to 5.0 mm, preferably 0.5 to 3 mm, and more preferably 0.5 to 2.0 mm.

[0032] The heat treatment of the surface of the main elastic layer 11 can form the covering layer 12, for example, by fitting the main elastic layer 11 into a mold and treating it at a high temperature. At that time, by providing holes at predetermined positions on the upper side of the mold, the expanded main elastic layer 11 bulges along the holes of the mold, and convex portions 13 as shown in FIG. 3 are formed. It is also possible to form larger convex portions 13 by compressing the main elastic layer 11 with the mold during the heat treatment and extruding the convex portions 13 from the holes. After that, by cutting the upper part of such convex portions 13, the inner main elastic layer 11 is exposed from the cut, and a breathable ventilation part 14 is formed. The ventilation part 14 receives the air supply and exhaust from the ventilation mechanism 19 connected to the air supply and exhaust ports 15, enabling ventilation to the pressing surface through the inside of the mattress 1.

[0033] The ventilation mechanism 19 has a connection part 191 connected to the air supply and exhaust port 15, a hose 192 connecting the connection part 191 and the ventilator 193, and a ventilator 193 that generates an air current. The ventilator 193 is a device for generating at least one of an air supply and an exhaust air current with respect to the mattress 1. When the air supply is performed, the air sent from the ventilator 193 reaches the main elastic layer 11 inside the mattress 1 and is discharged from the ventilation part 14 formed on the pressing surface. On the other hand, when the exhaust is performed, the intake is performed from the ventilation part 14, and this air current flows through the main elastic layer 11 into the ventilation mechanism 19 from the air supply and exhaust port 15 and is discharged to the outside. Note that any mechanism may be used for such a ventilator 193, and examples include a propeller fan, a blower, a cross-flow fan, etc. Also, the ventilator 193 may have a temperature control and humidity control function. The drive of the ventilator 193 can be performed by a switch, a controller, a remote control, etc. Also, the ventilator 193 may be attached by directly connecting the ventilator 193 to the air supply and exhaust port 15. Further, for example, the connection part 191 may be inserted in advance into the air supply and exhaust port 15, and then fixed by forming the covering layer 12.

[0034] As described above, according to this embodiment, by coating the main elastic layer 11 with the airtight covering layer 12 integrated with the surface of the main elastic layer 11, the air current can reach every corner inside the main elastic layer 11. Also, since the main elastic layer 11 and the covering layer 12 are integrated, no gap is generated between them, and no air current accumulates here. As a result, it is possible to sufficiently and efficiently ventilate the inside of a mattress that is generally difficult to dry easily and maintain a good sanitary state.

[0035] Also, since the covering layer 12 prevents the leakage and inflow of the air current from parts other than the ventilation part 14, it is possible to efficiently send the air current only to the ventilation part 14. In this example, the ventilation part 14 is provided only on the pressing surface that the user contacts, and the humidity and temperature around the human body can be comfortably adjusted. For example, when the user feels hot, a cold wind can be ventilated, and when the user feels cold, a warm wind can be ventilated to obtain a more comfortable sleeping comfort.

[0036] Furthermore, regarding the manufacturing method, since the main elastic layer 11 heat-treated and formed into a film is made to function as the coating layer 12, there is no need to separately prepare a coating material, a windproof cover, etc., or to form a flow path. Also, regarding the ventilation part 14, it is only necessary to remove the coating layer 12 at an arbitrary position and form an exposed part of the main elastic layer 11 on the surface, and it can be manufactured very simply.

[0037] Note that the position, number, size, shape, etc. of the ventilation part 14 may be configured in any way in consideration of the use, comfort, climate, etc. Also, the mattress manufacturing method is not limited to the above. For example, it is also possible to remove the coating layer 12 at an arbitrary position without forming a convex part, or to form the coating layer by insulating an arbitrary position during the heat treatment and not forming it, and using that part as the ventilation part 14.

[0038] Also, unevenness may be provided on the surface of the coating layer 12. In that case, for example, by providing the ventilation part 14 at the bottom of the concave part, ventilation can be further promoted. The location of the ventilation part 14 is not limited to the pressing surface, and by providing it at other positions, such as the bottom surface or the side surface, ventilation of parts that are usually in contact with a bed, a wall, a floor, etc. and have poor air permeability can also be achieved. Furthermore, the ventilation part 14 can be made into a cut instead of being punched out, and ventilation can be promoted from this cut. Such a cut increases air permeability because it shifts and creates a gap when a load is applied to the surface. Hereinafter, such a modification will be described.

[0039] <Modification 1 of Embodiment 1> FIG. 4 is a schematic view of a mattress 1a according to Modification 1 of Embodiment 1. The mattress 1a is obtained by fitting the main elastic layer into a mold with a substantially open upper surface, placing a heat insulating member on the open part, and performing heat treatment. The main elastic layer 11a expands and bulges from the opening, but since the part in contact with the heat insulating member does not melt and form a film-like shape of the main elastic layer 11, the coating layer 12a is not formed and functions as the ventilation part 14a as it is.

[0040] Further, the mattress 1a has ventilation openings 152 formed on the side surface, and a flow path 151 inside that connects the air supply and exhaust openings 15 and the ventilation openings 152 to each other. Note that the ventilation openings 152 can be opened and closed by plugs 153. When opened, air is preferentially blown into the flow path 151 to promote exhaust from the ventilation openings 152. When closed, air supply is evenly distributed throughout, increasing the ventilation volume from the ventilation section 14a.

[0041] According to such a method, a large ventilation section can be formed by a heat insulating member. In this example, since the ventilation section 14a is formed only by heat treatment, the labor of removing the coating layer 12 can be saved. Also, by combining the heat insulating member and the heat conductive member, it is possible to form ventilation sections with more diverse shapes. Furthermore, by providing the flow path 151 and the ventilation openings 152, ventilation can be preferentially performed at an arbitrary position. Also, by opening and closing the ventilation openings 152, it is possible to adjust the ventilation volume in each part.

[0042] <Modification Example 2 of Embodiment 1> FIG. 5 is a schematic view of a mattress 1b according to Modification Example 2 of Embodiment 1. The mattress 1b is obtained by heat treating the main elastic layer to form a coating layer 12b over the whole, and then dividing it into two parts vertically. Note that since the cross section (pressing surface) is in a state where the main elastic layer 11b is exposed, the cross section functions as the ventilation section 14b as it is. At that time, by making the cross section wavy by profile processing, the pressure applied to the surface during loading can be dispersed, and higher breathability can be ensured. Note that profile processing is a processing method in which a sponge is alternately compressed from above and below with a roller having unevenness, and a slicing blade is inserted in the middle for slicing. When compressed and then released, the mechanism is such that unevenness is formed on the sliced surface. When adopting such a manufacturing process, since two mattresses are obtained from one main elastic layer, it is necessary to perform heat treatment on the main elastic layer 11b having a thickness for two mattresses in advance. Also, air supply and exhaust openings 15 are provided on the side surfaces of each of the mattresses divided vertically.

[0043] According to such a method, the heat treatment for two mattresses and the formation of the ventilation part can be carried out at once. Further, by making the pressing surface wavy, the pressure due to the user's body weight is dispersed, so the airflow in the ventilation part 14b is hardly obstructed, and a comfortable sleeping experience can be obtained. Note that the means for making the surface wavy does not necessarily have to be profile processing, and for example, laser cutting processing may be used.

[0044] <Embodiment 2> FIG. 6 is a schematic view showing an example of a mattress according to Embodiment 2. The mattress 2 is formed by combining elastic layers of different materials. Specifically, a main elastic layer 21 located on the pressing surface side and having a profiled surface (ventilation part 24), and a sub-elastic layer 26 located on the bottom surface side and provided with air supply and exhaust ports 15 on the side surface are laminated. Hereinafter, the description will focus on the differences from the above Embodiment 1, and duplicate descriptions will be omitted as appropriate.

[0045] The sub-elastic layer 26 is an elastic body made of a material different from that of the main elastic layer 21, or having different properties (such as Newton number) even if it is the same material. The sub-elastic layer 26 is disposed below the main elastic layer 21 and is formed of a breathable elastic body having an appropriate thickness and elasticity to support the main elastic layer 21. As with the main elastic layer 21, the material can be an elastic body using a synthetic resin having thermoplasticity or thermosetting properties, for example, foam materials such as polyethylene foam, rubber sponge, urethane foam, or fibers. Note that the sub-elastic layer 26 and the main elastic layer 21 are laminated so as to be mutually ventilable in the vertical direction inside. Also, here, the sub-elastic layer 26 has higher breathability than the main elastic layer 21.

[0046] The manufacturing method of such a mattress 2 is, for example, first, the main elastic layer 21 is laminated so as to be sandwiched by the sub-elastic layer 26, and the surface is heat-treated. Then, the surfaces of the main elastic layer 21 and the sub-elastic layer 26 are melted and formed into a film shape, and an airtight coating layer 22 is integrally formed. Thereafter, the main elastic layer 21 is vertically divided into two by profile processing, and the main elastic layer 21 is exposed on the cross section (pressing surface). The wavy pressing surface of this main elastic layer 21 functions as the ventilation part 24.

[0047] On the side surface of the auxiliary elastic layer 26, an air supply and exhaust port 25 connected to the ventilation mechanism 8 is formed. Further, in this example, an air supply and exhaust port 25 is also formed on the opposite side surface (not shown). The first connection part 711 and the second connection part 811 of the ventilation mechanism 8 are fixed to these two air supply and exhaust ports 25 by pins 720 respectively. By supplying air from the air supply and exhaust port 25 on the first connection part side and exhausting the air from the air supply and exhaust port 25 on the second connection part side, higher ventilation performance can be obtained. Although the positions of both air supply and exhaust ports are not particularly limited, it is preferable to arrange them at opposite positions in the mattress so that the air flow can reach every corner inside.

[0048] The configuration of the ventilation mechanism 8 is not particularly limited as long as it can blow air into the main body of the mattress 2 and suck air from the main body. Preferably, the ventilation mechanism 8 can reuse the sucked air for blowing air into the main body and circulate the air. As an example, in addition to the blowing part, the ventilation mechanism 8 may be provided with at least one of a cleaning part, a temperature adjusting part, and a humidity adjusting part, enabling cleaning, heating, humidifying, etc.

[0049] FIG. 7 is an explanatory diagram for explaining the air flow of the mattress according to Embodiment 2. As shown in FIGS. 6 and 7, the ventilation mechanism 8 of this embodiment includes a duct part 81 and a housing 82. The duct part 81 has an air supply duct 811 detachably connected to the first connection part 711 and an exhaust duct 812 detachably connected to the second connection part 712. Further, the ventilation mechanism 8 has a power supply part (not shown). Furthermore, the ventilation mechanism 8 includes, in the housing 82, in order from the exhaust duct 812 side (exhaust side), a cleaning part 83, a blowing part 84, a temperature adjusting part 85, a humidity adjusting part 86, and an adjusting part 87. Also, the ventilation mechanism 8 is provided with an adjusting valve 88 for adjusting the intake of outside air on the housing 82.

[0050] The purification unit 83 is a component for purifying air and is arranged near the exhaust duct 812. As an example, the purification unit 83 has a first air filter 831 for capturing relatively large particles (such as dust) from the exhausted air, and a second air filter 832 for capturing finer particles than the first air filter 831. The second air filter 832 is arranged on the air supply duct side (air supply side) of the first air filter 831. The other configurations of the first air filter 831 and the second air filter 832 are not particularly limited as long as they perform the above functions.

[0051] The air blowing unit 84 has a fan and a motor for driving the fan, sucks air from the exhaust side, blows out the air to the air supply side, and generates an air flow to the air supply side. The operation start and stop of the air blowing unit 84 are controlled by a controller 89 described later. The air blowing unit 84 may be configured to be able to control the air volume.

[0052] The temperature regulating unit 85 has a heating element and can heat the air to be blown, that is, the air blown out from the air blowing unit 84 and passing through. The operation start and stop of the temperature regulating unit 85 are controlled by a controller 89 described later.

[0053] The ventilation mechanism 8 may include a heat exchanger as a temperature regulating unit and heat the or cool the air to be blown by the heat exchanger. The heat exchanger is not particularly limited, and known technologies can be used as appropriate. The heat exchanger utilizes, for example, latent heat of evaporation. The heat exchanger uses, for example, a compressor. A part of the temperature regulating unit may be provided outside the housing 82 and externally connected. For example, an outdoor unit may be provided or connected to the outdoor unit of an air conditioner for external connection. In addition, a ventilation function at a high temperature (50 °C or higher, preferably 60 °C or higher) for killing mites may be provided.

[0054] The humidity control unit 86 includes a humidifying filter and a water storage tank. The humidifying filter is immersed in the water in the water storage tank, and water permeates throughout by capillary action. The air passing through the humidity control unit 86 is supplied with moisture and humidified by the humidifying filter. The water storage tank has a float valve and is designed to keep the water level constant. The ventilation mechanism 8 has a water supply tray (not shown) detachably attached to the housing 82, enabling water supply to the water storage tank.

[0055] The adjustment unit 87 has an adjustment filter and finally adjusts (agitates) the air being blown.

[0056] As an example, the controller 89 for controlling the operations of the above components is provided at the upper part of the housing 82, has an operation unit, and is operable by the user. The controller 89 has, for example, a microcomputer equipped with a processor such as a CPU and memories such as RAM and ROM, and the processor executes a program stored in the memory, for example, to exhibit its functions.

[0057] The ventilation mechanism 8 has a sensor unit 90 for adjusting the temperature and humidity of the supply air to a predetermined value (or a predetermined range) according to the user's request (setting). The sensor unit 90 includes, as an example, a supply air side sensor unit 901 provided at the base of the supply air duct 811 and an exhaust air side sensor unit 902 provided at the base of the exhaust air duct 812.

[0058] The supply air side sensor unit 901 has a temperature sensor for detecting the supply air temperature by detecting the temperature at the base of the supply air duct 811 in the supply air and a humidity sensor for detecting the supply air temperature by detecting the humidity at the base of the supply air duct 811 in the supply air. The exhaust air side sensor unit 902 has a temperature sensor for detecting the current (exhaust) temperature of the main body of the connected mattress 1 by detecting the temperature at the base of the exhaust air duct 812 and a humidity sensor for detecting the current (exhaust) temperature of the main body of the mattress 1 by detecting the humidity at the base of the exhaust air duct 812. Although not shown here, one or more of the above temperature sensors and humidity sensors may be installed in the mattress and connected to and controlled by the ventilation mechanism 8.

[0059] Based on the current temperature and humidity and the set temperature and humidity, the controller 89 turns the above components on and off to control the supply air temperature and humidity. For example, when the current temperature is lower than the set temperature and the current humidity is lower than the set humidity, humidified warm air is automatically blown, and when the set temperature and humidity are reached, the blowing stops. The controller 89 may have a display unit so that the user can check the supply air temperature and humidity, etc.

[0060] During the operation of the ventilation mechanism 8, an air flow (air current, wind) as shown by the arrow in FIG. 7 is formed. That is, the air inside the mattress 2 is taken into the housing 82 from the exhaust duct 812 by the blower unit 84, passes through the cleaning unit 83, and the air blown out by the blower unit 84 passes through the temperature adjusting unit 85, the humidity adjusting unit 86, and the adjusting unit 87 and is adjusted, and then is sent from the supply air duct 811 to the main body of the mattress 2. The air sent into the main body of the mattress 2 from the first connection part 711 enters the sub-elastic layer 26, further ventilates upward through the main elastic layer 21 and is discharged from the ventilation part 24, or ventilates horizontally and refluxes to the ventilation mechanism 8 again from the second connection part 712. Note that the strength of the air current flowing out from each place varies depending on the supply air volume from the ventilation mechanism 8, the high air permeability of the main elastic layer 21 and the sub-elastic layer 26 (depending on the material, the amount of voids, the shape, etc.), the position of the air supply and exhaust ports 25, etc., and thus can be arbitrarily designed. In this example, since the sub-elastic layer 26 has higher air permeability than the main elastic layer 21, reflux is likely to occur even when the power of the ventilation mechanism 8 is small, and noise can be reduced. Fresh outside air is appropriately sucked in through the regulating valve 88.

[0061] According to such a mattress 2, the corrugated main elastic layer 21 disperses the pressure applied to the pressing surface, and since the concave part of the corrugation is difficult to be completely covered by the human body, the air permeability of the bottom part of the concave part is less likely to decrease. Therefore, high air permeability can be ensured even at the contact part between the user and the mattress. As a result, the user can more easily receive an air current on the body and achieve a comfortable sleep.

[0062] Furthermore, according to the mattress 2 of the present embodiment, by combining different elastic layers, various comfortable mattresses can be designed. In addition, the user can optimize the temperature and humidity to obtain high-quality sleep in a comfortable environment. Also, the inside of the mattress 2 can be ventilated to every corner to keep it clean.

[0063] The mattress 1 can be simply temperature-controlled by putting a cold storage agent for cooling in summer and a heat-insulating material for warming in winter in the ventilation mechanism 8. Also, a storage part for storing heat, storing moisture, and promoting drying can be provided inside the mattress. The storage part is, for example, a space or layer in which a drug or the like having a cold storage and drying effect is contained or coated on the mattress material itself, or a cold storage agent or a desiccant can be directly put in. Thereby, for example, before use, the ventilation mechanism 8 is operated to adjust the heat and moisture inside the mattress, and during use, by stopping, intermittently operating, or operating at low power the ventilation mechanism, a comfortable sleeping comfort with low noise can be obtained. In addition, a device capable of heating and cooling can be separately connected to the ventilation mechanism 8. Also, for example, the ventilation mechanism 8 may have a function of adjusting the strength of the air volume, an intermittent air supply (rhythm air supply) function, and a timer function. Furthermore, by making an air filter or the like absorb or suck an anti-odor agent or an insect repellent and circulating the air, the inside of the main body can be kept clean.

[0064] Note that the combination of the sub-elastic layer 26 and the main elastic layer 21 is not limited to the above. As long as air permeability is ensured between them, they can be laminated or combined in any number of ways. Furthermore, different elasticities, air permeabilities, and materials can be combined. Also, as another material, for example, a cushion material such as felt or resin fiber can be bonded.

[0065] Also, by connecting a plurality of mattresses 2 in series or in parallel to the ventilation mechanism 8, they can be ventilated together. Furthermore, the hardness of the elastic layer can be changed according to the position, or a structure more suitable for ventilation can be added. Furthermore, the formation of the coating layer is not limited to the above, and a film integrated with the elastic layer can be adopted by various methods. Hereinafter, such a modification will be described.

[0066] <Modification Example 1 of Embodiment 2> FIG. 8 is a schematic view showing an example of the mattress 2a according to Modification Example 1 of Embodiment 2. The mattress 2a is formed by connecting three mattresses 2 side by side in the horizontal direction. The mattresses 2 are connected and fixed to each other by a connecting portion 713 which is a hollow cylindrical member, and the inside of the connecting portion 713 serves as a flow path for the air flow, allowing the air flow to reach the inside of all the mattresses 2. Here, the mattress 2a is composed of three mattresses, but it may be divided into any number.

[0067] As a result, even for a large-sized mattress, since it can be disassembled into each mattress part for handling, it can be manufactured and transported more simply. Also, by making the connecting portion 713, the connecting portion 711, and the connecting portion 712 compatible with each other and configuring them to be detachable from each other, it is possible to replace only the damaged or soiled part of the mattress. Further, when the load is always applied to the same position, in order to prevent only a specific part from deteriorating, it is also possible to appropriately exchange the positions and directions of each mattress for use.

[0068] Note that the connecting method is not limited to the above. For example, a coating layer may not be formed on the connecting side surface of the elastic layer, and it may be connected with a connecting part or the like. Also, the elastic layer itself may be molded into a shape that can be incorporated into each other (for example, a hook shape), and combined and connected to each other.

[0069] <Modification Example 2 of Embodiment 2> FIG. 9 is a schematic view showing an example of the mattress 2b according to Modification Example 2 of Embodiment 2. The mattress 2b includes a main elastic layer 21b composed of a hard portion 211 including at least a part of each convex portion of the corrugation on the pressing surface and a soft portion 212 of the other part. Note that the hard portion 211 has a higher hardness (for example, Newton number) than the soft portion 212.

[0070] The hard portion 211 is a part above the corrugated convex portion. For example, in the mattress 2b shown in FIG. 9, the height of the hard portion 211 (the height from the apex C of the convex portion to the boundary surface B of the soft portion 212) is about 70% of the overall height of the convex portion (the height from the apex C of the convex portion to the base surface A from which the convex portion rises). Note that the height of the hard portion 211 (i.e., the position of the boundary surface B) can be freely changed during manufacturing. However, in order to obtain the effects of this example, the height of the hard portion 211 is preferably 30 to 90% of the upper side of the convex portion, more preferably about 60 to 80%.

[0071] Note that the main elastic layer 21b having the hard portion 211 and the soft portion 212 can be obtained by laminating different members with different hardnesses and performing profile processing on this. Note that the same material may be made to have different hardnesses by changing the structure and the expansion ratio. For example, the expansion ratio of the soft portion 212 is made higher than the expansion ratio of the hard portion 211. Also, it may be integrally formed such that the expansion ratio changes stepwise on the upper side and the lower side of the same main elastic layer.

[0072] In such a main elastic layer 21b, when the weight of the user is applied, the hard portion 211 sinks while maintaining a certain shape to some extent. When this is received by the soft portion 212, the vicinity of the root of the convex portion bends unevenly and a flow path is opened, making it easier for air flow to flow around. As a result, in the vicinity of the load applied by the user, a flow path can be secured particularly at the bottom portion of the concave portion, and air flow can be efficiently generated also at the contact portion between the user and the mattress.

[0073] <Modification Example 3 of Embodiment 2> FIG. 10 is a top view showing an example of a mattress according to Modification 3 of Embodiment 2, and a cross-sectional view of the cross-section taken along line D-D' as viewed from the arrow direction. The mattress 2c has a plurality of ventilation valves 27 penetrating the main elastic layer 21c in the vertical direction at the bottom of the wave-shaped recesses of the main elastic layer 21c. The ventilation valve 27 is, for example, a Y-shaped cut, and can be formed by cutting the main elastic layer 21c in the vertical direction evenly at approximately 120-degree intervals in three directions from the center E of the bottom portion of the recess. Here, a Y-shaped cut is used, but for example, a circular or polygonal cylindrical cut may also be used.

[0074] The ventilation valve 27 can change the ventilation volume in the vicinity of the pressing surface depending on the presence or absence of a load. Specifically, as shown in the lower figure of FIG. 10, the ventilation valve 27 is closed in the unloaded portion, and almost no void is generated. On the other hand, in the loaded portion, the convex portion collapses and the ventilation hole 28 opens. Since this becomes the flow path from the sub-elastic layer 26 to the main elastic layer 21c, the airflow mainly increases in the vicinity of the loaded portion.

[0075] In this way, the mattress 2c of this embodiment can secure a flow path in the loaded portion where the airflow is easily obstructed, and can adjust the temperature and humidity in the vicinity of the human body. As a result, the moisture generated by the human body can be efficiently dried, or the contact portion can be intensively warmed or cooled.

[0076] <Modification 4 of Embodiment 2> FIG. 11 is a schematic view showing an example of a mattress 2d according to Modification 4 of Embodiment 2. In the mattress 2d, the surfaces of the laminated main elastic layer 21 and sub-elastic layer 26 are covered with a covering material 22d, and a covering layer is formed by heat-treating this.

[0077] In the method of melting and solidifying the surface of the elastic layer by heat treatment to form a film, when the elastic layer has a high foaming ratio and is a rough material, it may not be possible to coat it uniformly, or holes may remain through which the air flow inside the mattress leaks. Therefore, the entire body can be covered with a coating material 22d having thermoplastic or thermosetting properties, and a coating layer can be formed by heat-treating this. The coating material 22d can be any material as long as it is suitable for the film, for example, a synthetic resin sheet that can form a coating with a low foaming ratio and uniformity. Note that as a method of covering the elastic layer, for example, winding or packing can be used.

[0078] According to such a method, since the quality of the coating layer does not depend on the configuration and material of the elastic layer, the selection range of the elastic layer is widened. In particular, since the elastic layer does not necessarily need to have thermoplastic or thermosetting properties, it becomes possible to use fibers such as coconut husks, wires, etc., and resins with high melting points. Also, when using a material not suitable for heat treatment, the elastic layer may be coated by adhering and attaching the coating material 22d to the elastic layer without gaps.

[0079] Furthermore, the formation of the coating layer is not limited to the method described above. For example, a method of applying a liquid coating material to cover the surface of the elastic layer and then solidifying (drying) it may be adopted. For example, it is a method of uniformly coating the surface of the elastic layer by dipping, spraying, painting, sputtering, etc., and solidifying this to form a coating layer. The coating layer uses a material having flexibility to deform as the elastic layer deforms. The coating layer may be the same as the material constituting the elastic layer. According to such a method, since heat treatment is not required, a large-scale device is not necessary, and a simple manufacturing process can be selected.

[0080] In this way, by forming a film integrally with the elastic layer, the air flow can be distributed throughout the entire mattress, enabling efficient air blowing to the user.

[0081] Based on the above description, those skilled in the art may be able to conceive of additional effects and various modifications of the present invention. However, the aspects of the present invention are not limited to the examples of the above-described embodiments. Various additions, changes, and partial deletions are possible without departing from the conceptual ideas and spirit of the present invention derived from the content defined in the claims and their equivalents.

Explanation of Reference Numerals

[0082] 1,2 Mattress 11,21 Main Elastic Layer 12,22 Coating Layer 13 Protrusion 14,24 Ventilation Port 15,25 Air Supply and Exhaust Port 19,8 Ventilation Mechanism 26 Sub-Elastic Layer 81 Duct Portion 82 Housing 83 Cleaning Portion 84 Air Blowing Portion 85 Temperature Adjustment Portion 86 Humidity Adjustment Portion 87 Adjustment Portion 88 Control Valve 89 Controller 90 Sensor Portion

Claims

1. A mattress comprising a breathable elastic layer and a non-breathable covering layer, the covering layer is a coating that is integrated with the elastic layer and covers the surface of the elastic layer, a ventilation portion that is not covered by the covering layer, A ventilation mechanism exhausts the air supplied to the elastic layer from the ventilation section, or exhausts the air supplied to the ventilation section from the elastic layer. A mattress characterized by:

2. The ventilation mechanism draws the supplied air from another position.

2. The mattress of claim 1.

3. The covering layer is formed by subjecting the surface of the elastic layer to a heat treatment to form a film. A mattress according to claim 1 or 2.

4. The ventilation portion is a portion where the elastic layer is not partially formed into a film.

4. The mattress of claim 3.

5. The ventilation portion is a portion where the covering layer is partially removed.

4. The mattress of claim 3.

6. The ventilation portion is a cut surface formed by cutting the elastic layer.

4. The mattress of claim 3.

7. The ventilation portion is an uneven surface formed by cutting the elastic layer through a profile process.

7. The mattress of claim 6.

8. The covering layer is formed by forming a film of a covering material covering the surface of the elastic layer by heat treatment. A mattress according to claim 1 or 2.

9. The coating layer is formed by forming a coating film on the surface of the elastic layer using a liquid coating material. A mattress according to claim 1 or 2.

10. The elastic layer includes a main elastic layer and a sub-elastic layer having higher air permeability than the main elastic layer, and the ventilation mechanism is connected to the sub-elastic layer. A mattress according to claim 1 or 2.

11. The ventilation mechanism includes at least one of an air purifying unit, a temperature adjusting unit, a humidity adjusting unit, and a heat exchanger. A mattress according to claim 1 or 2.

12. The mattresses are connected to each other in a transverse direction so as to be breathable. A mattress according to claim 1 or 2.

13. The ventilation portion formed in a corrugated shape by the profile processing has a portion from the upper side of the protrusion that has a higher hardness than the other portion.

8. The mattress of claim 7.

14. The ventilation portion formed in a corrugated shape by the profile processing has a valve at the bottom of the recess that opens and closes depending on the presence or absence of a load.

8. The mattress of claim 7.

15. A method for manufacturing a mattress comprising a breathable elastic layer, a non-breathable covering layer covering the elastic layer, and a ventilation section not covered by the covering layer, wherein air supplied to the elastic layer is exhausted from the ventilation section, or air supplied to the ventilation section is exhausted from the elastic layer, by a ventilation mechanism, comprising: A) The surface of the elastic layer is turned into a film by heat treatment, a) forming a film of the covering material covering the surface of the elastic layer by heat treatment; or C) applying a liquid coating material onto the surface of the elastic layer and then solidifying the material to form a coating; forming the coating layer integrally with the elastic layer to cover the surface; How a mattress is manufactured.

16. forming the ventilation portion by cutting or removing the coating layer; A method for manufacturing a mattress according to claim 15.

17. The elastic layer includes a main elastic layer and a sub-elastic layer having higher air permeability than the main elastic layer and to which the ventilation mechanism is connected, A step of laminating the primary elastic layer and the secondary elastic layer and cutting the primary elastic layer by profile processing. A method for manufacturing a mattress according to claim 16.

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