Mattress and order reception method of mattress

Abstract

To provide a mattress in which vibration is hard to be transmitted among different cushion bodies.SOLUTION: Provided is a mattress including a cushion for a mattress. A plurality of persons can be laid on the cushion for the mattress in a horizontal direction. The cushion for the mattress includes a plurality of cushion bodies that can be separated in the horizontal direction. Each of the cushion bodies is formed of a filament three-dimensional connected body including a plurality of filaments, and has a contact surface that contacts the adjacent other cushion body. An end portion of the filament of each of the plurality of cushion bodies does not extend to the inside of the adjacent other cushion body.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mattress formed using a cushion body and a method for receiving orders for the mattress.

Background Art

[0002] In recent years, a high-resilience mattress using a conjugate body (filament three-dimensional conjugate body) obtained by three-dimensionally fusion-bonding filaments made of a thermoplastic resin has attracted attention because it has a high resilience, is easy to turn over, and has excellent breathability.

[0003] In addition, since the filament three-dimensional conjugate body has a high porosity (generally about 95%), it can be quickly drained and dried even when washed with water, and thus has the advantage of being easy to clean.

[0004] As a method for manufacturing such a filament three-dimensional conjugate body, for example, the method disclosed in Patent Document 1 is known. According to this method, after extruding molten thermoplastic resin downward in the vertical direction from a plurality of horizontally arranged nozzles, a molten filament having a diameter of about 1 mm is dropped into cooling water to form a loop by the buoyancy of water. At the same time, a plurality of loop-formed molten filaments are three-dimensionally fusion-bonded to each other, and then cooled and solidified to produce a filament three-dimensional conjugate body. By regulating the thickness of a plurality of molten filaments using a roller or a metal plate at the timing of three-dimensionally fusion-bonding the plurality of molten filaments to each other, a filament three-dimensional conjugate body having a desired thickness can be obtained. Immediately after manufacturing, it becomes a continuous filament three-dimensional conjugate body having a thickness corresponding to the interval between the roller and the metal plate. Therefore, a cushion for a mattress can be obtained by cutting so that the length direction (the traveling direction of the molten filament group) and the width direction (the direction perpendicular to the thickness direction and the length direction) have desired sizes.

Prior Art Documents

Patent Documents

[0005] Patent Document 1 Japanese Patent No. 4966438 Patent Document 2 International Publication No. 2018 / 150815 SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0006] However, since the mattress using the filament three-dimensional conjugate has a high resilience, when two people go to bed on a general double bed mattress 5 (composed of a single cushion body 51 and a mattress cover 50) as shown in FIG. 30, when one user turns over, as shown by the white arrow in FIG. 30, there is a problem that the vibration (vertical vibration) during turning over is likely to be transmitted to the other user.

[0007] On the other hand, if a mattress 6 as shown in FIG. 31, for example, a 6-division type mattress as described in FIG. 12 of Patent Document 2 is used, two users can go to bed on different cushion bodies 61, 62 respectively. The cushion bodies 61, 62 are covered with a mattress cover 60.

[0008] However, since the filament three-dimensional conjugate has a high porosity of 90% to 98% and thus has many gaps, at the contact surfaces 61F, 62F of the adjacent cushion bodies 61, 62 in the left-right direction, a part of the filaments of one cushion body (especially, the cut end of the filament or the loop convex part of the filament) enters into the filaments of the other cushion body, and they are in an engaged state.

[0009] As a result, a large frictional force (engagement force) is generated on the contact surface. Therefore, as shown in FIG. 32, when a load W is applied to one cushion body and it deforms, the other cushion body also tends to deform in conjunction, and it was not possible to sufficiently suppress the transmission of the vibration during turning over by one user to the other user. In FIG. 32, the state when the load W is applied to the cushion body 61 is shown on the right side, and the state when the load W is not applied is shown on the left side.

[0010] Furthermore, when the cushion bodies are accommodated so as to be compressed by the mattress cover 60 so that the gap between the cushion bodies adjacent in the left-right direction does not widen and hands and feet do not fall in, the frictional force (engagement force) of the contact surfaces of the plurality of cushion bodies 61, 62 increases further, and there is a problem that the vibration during turning over is more likely to be transmitted.

[0011] In view of the above problems, an object of the present invention is to provide a mattress in which vibration is difficult to be transmitted between different cushion bodies, and an order receiving method for the mattress.

Means for Solving the Problems

[0012] The mattress according to the present invention has a mattress cushion, and is a mattress on which a plurality of people can lie horizontally in the left-right direction on the mattress cushion. The mattress cushion includes a plurality of cushion bodies that are separable in the left-right direction. Each of the plurality of cushion bodies is formed of a filament three-dimensional conjugate body composed of a plurality of filaments, has a contact surface that contacts another adjacent cushion body, and the ends of the filaments of each of the plurality of cushion bodies are configured not to enter into another adjacent cushion body.

[0013] According to this configuration, on the contact surface of the cushion bodies adjacent in the left-right direction, the contact friction force generated by the end portion of the filament of one cushion body (the cut end portion of the filament or the loop convex portion of the filament) entering into the filament of the other cushion body can be reduced. Therefore, it is possible to suppress the vibration during turning over by one user from being transmitted to the other user. More specifically, as this configuration, each of the plurality of cushion bodies may be configured such that the end portion of the filament does not protrude outside the contact surface in all regions of the contact surface.

[0014] In the above configuration, the resilience of the plurality of cushion bodies may be 100 N or more and 200 N or less respectively, and the contact friction force on the contact surface between the adjacent cushion bodies may be more than 0 N and less than 50 N. According to this configuration, since the contact friction force is less than 50 N, by using a cushion body with a resilience of 100 N or more and 200 N or less, the amplitude of vibration is significantly attenuated on the contact surface. Therefore, it is possible to further suppress the vibration during turning over by one user from being transmitted to the other user.

[0015] Note that the resilience in the present invention can be measured by the following method. First, place the sample to be measured on a horizontal table, measure the thickness of the sample when it is not compressed, and denote it as L1 (mm). Then, bring a rod-shaped pressing member (load cell) with a circular plate having a diameter of 150 mm horizontally provided at the tip into vertical contact with the center of the upper surface of the sample, apply a load to the load cell, and compress the sample in the thickness direction. At that time, as the thickness of the sample during compression, measure the distance L2 (mm) between the bottom surface of the sample (the upper surface of the horizontal table) and the tip of the load cell (circular plate). When L2 becomes 7.5 mm shorter than the thickness L1 (mm) of the sample when it is not compressed (L2 = L1 - 7.5), measure the load including the weight of the load cell as a value, and take that value (N) as the resilience.

[0016] In addition, the contact friction force in the present invention can be measured by the following method. First, as samples to be measured, two adjacent cushion bodies are each cut into a rectangular parallelepiped with a horizontal plane of a 20-cm square, leaving the contact surface. The two cut cushion bodies are each sandwiched between two square plates with a side length of 20 cm in the thickness direction (vertical direction), and a pressure of 1000 Pa is applied to the metal plates to fix each cushion body. At this time, a 2-cm gap is provided and fixed between one side of the metal plate and the contact surface of the cushion body so that the contact surface is not hidden by the metal plate. The two cushion bodies are brought into contact with each other at the contact surface, and the two cushion bodies are pressurized from both sides so that a pressure of 200 Pa is applied in the direction perpendicular to the contact surface. With the contact surface in contact under a pressure of 200 Pa, a shearing force is applied in the thickness direction of each cushion body, and a force is applied from the center of the metal plate in a direction parallel to the contact surface to slide each cushion body 5 cm in the thickness direction. The maximum value (N) of the force applied at that time is defined as the contact friction force.

[0017] In addition, in the above configuration, each of the plurality of cushion bodies may be configured to have a smooth surface layer on the contact surface. According to this configuration, since there are no cut ends (cuts) of the filaments on the contact surface, not only the static contact friction force but also the dynamic contact friction force can be reduced. Therefore, even when vibrations with a large amplitude occur, it is difficult for the vibrations to be transmitted on the contact surface. Here, the smooth surface layer is a layer up to a depth of 2 mm from the surface of the cushion body, and has a higher bulk density than the inside thereof, and is a layer in which the cut ends (cuts) of the filaments do not protrude outward from the surface.

[0018] The mattress according to the present invention is a mattress including a cushion for a mattress composed of a plurality of cushion bodies and a mattress cover for accommodating the cushion for a mattress. The cushion for a mattress includes a plurality of separable cushion bodies, and at least one or more of the plurality of cushion bodies include electronic components having a communication function. Each of the plurality of cushion bodies is formed of a three-dimensional filament aggregate composed of a plurality of filaments, has a contact surface that contacts another adjacent cushion body, and is configured such that the ends of the filaments of each of the plurality of cushion bodies do not enter into another adjacent cushion body.

[0019] Although the installation location of the cushion body including the electronic component having the communication function can be determined according to the user's preference, since the separable cushion body made of the three-dimensional filament aggregate has a large contact frictional force, it takes time to fit the cushion body into a predetermined position, or it cannot be completely fitted, resulting in a problem of a step. In this regard, according to this configuration, the contact frictional force of the cushion body including the electronic component having the communication function can be reduced, so that it becomes easy for the user to fit the cushion body into a desired position. More specifically, as the configuration, each of the plurality of cushion bodies may be configured such that the ends of the filaments do not protrude outside the contact surface in all regions of the contact surface.

[0020] Moreover, the method for receiving an order for a mattress according to the present invention is a method for receiving an order for a mattress having the above-described configuration in which a plurality of cushion bodies are housed in a mattress cover, and includes a cushion information input reception step of receiving, at a first communication terminal on the orderer side, input of cushion information which is information regarding the cushion bodies for each section in which the plurality of cushion bodies are respectively arranged, a cushion information transmission step of transmitting the input received cushion information to a second communication terminal on the order receiver side, a cushion information reception step of receiving the transmitted cushion information at the second communication terminal, and a mattress cover model number determination step of determining the model number of the mattress cover based on the received cushion information. The cushion information includes at least information on the shape of the cushion bodies for each section. According to this method, even when ordering a mattress including cushion bodies with different shapes, it is possible to prevent an order mistake such as the mattress cover not fitting.

Advantages of the Invention

[0021] According to the mattress of the present invention, vibration is less likely to be transmitted between different cushion bodies. Also, according to the method for receiving an order for a mattress of the present invention, the convenience when ordering a mattress having the above-described effects is improved.

Brief Description of the Drawings

[0022]

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MODE FOR CARRYING OUT THE INVENTION

[0023] Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings.

[0024] 1. First Embodiment First, the first embodiment will be described. FIG. 1 is a perspective view of a mattress 1 according to the first embodiment. In addition, each direction of up - down, left - right, and front - back regarding the mattress 1 is as shown in FIG. 1. In FIG. 1, in order to make it easy to understand the internal configuration of the mattress 1, the schematic positions of the respective cushion bodies 21 to 26 are shown by broken lines.

[0025] The mattress 1 includes a mattress cover 10 that covers the entire outer surface thereof and a mattress cushion 20 housed therein. The mattress 1 as a whole has a rectangular parallelepiped shape with sides in the front-back direction (length direction), left-right direction, and up-down direction (thickness direction). The left-right dimension is slightly smaller than the front-back dimension, and the up-down dimension is sufficiently smaller than the left-right dimension.

[0026] The mattress cushion 20 is composed of cushion bodies 21 to 26 formed by a total of six filament three-dimensional conjugates divided into two in the left-right direction and three in the length direction.

[0027] The mattress 1 according to the first embodiment is usually placed on a horizontal floor, bed, etc., and is used in a form where two users lie side by side in the left-right direction on the upper side of the mattress 1. When used in this way, the up-down direction of the mattress 1 coincides with the vertical direction. The mattress 1 can be preferably used by setting the size in the front-back direction to be substantially the same as the height direction of the user, but the sizes in the front-back direction and the left-right direction can be freely changed according to preference.

[0028] The mattress cover 10 has an upper surface side cover 11, a bottom surface side cover 12, and a fastener 13. With the mattress cushion 20 placed inside the upper surface side cover 11 and the bottom surface side cover 12, the upper surface side cover 11 and the bottom surface side cover 12 are joined by the fastener 13.

[0029] The fastener 13 is configured to be less stretchable than other parts of the mattress cover 10 and serves to prevent the peripheral length of the mattress cover 10 from stretching (serves as an anti-stretching member). The fastener 13 is provided so as to have a substantially constant up-down position (height) and go around the outer peripheral surface of the mattress cover 10 when viewed from above.

[0030] In this embodiment, a fastener using a fabric tape as an anti-elongation member is used, and this fastener is arranged so as to cover the entire joint portion between the upper surface side cover 11 and the bottom surface side cover 12. By opening the fastener 13, the upper surface side cover 11 and the bottom surface side cover 12 can be completely separated.

[0031] The anti-elongation member exemplified by the fastener 13 prevents the elongation of the mattress cover 10 in the length direction, and prevents the widening of the gaps between the cushion bodies 21 to 26 due to the elongation of the mattress cover 10. Note that the anti-elongation member is not limited to completely preventing such elongation. The anti-elongation member needs to be a member with an elongation of 2 cm or less per 1 m when pulled with a force of 100 N, and preferably a member with an elongation of 1 cm or less per 1 m.

[0032] In particular, on the side surfaces (left and right side surfaces) parallel to the length direction (usually corresponding to the user's height direction), it is preferable that the elongation is 0.5 cm or less per 1 m when pulled with a force of 100 N. Examples of materials that can be used as the anti-elongation member include fabric tapes formed of chemical fibers.

[0033] As the position for attaching the anti-elongation member, at a height within the range of 50 to 99% (a position closer to the upper surface portion 11a than the center) at the height from the bottom surface portion 12a to the upper surface portion 11a (FIG. 2 described later), it is preferably provided continuously in the circumferential direction when viewed from above. In this case, the anti-elongation member is preferably disposed so as to continuously surround the peripheral surface portion 10A of the mattress cover 10 including two side surfaces (left and right side surfaces) parallel to the length direction.

[0034] This embodiment is configured to employ a belt-shaped anti-elongation member. However, in addition to such a configuration, for example, the entire peripheral surface portion 10A may be designed to function as an anti-elongation member using a canvas fabric or the like. Further, in order to improve the air permeability, it is desirable to provide a plurality of ventilation holes or a mesh fabric with excellent air permeability on the peripheral surface portion 10A.

[0035] The shapes of the upper surface portion 11a and the bottom surface portion 12a are not limited to rectangles as in the present embodiment, and may be, for example, shapes in which the four corners of a rectangle are rounded. In this case, in the peripheral surface portion 10A, the boundary portions (sides extending vertically) between the respective side surfaces on the front, rear, left, and right may be rounded in the same manner.

[0036] FIG. 2 is an exploded perspective view of the mattress cover 10 in FIG. 1. More specifically, FIG. 2 is a schematic exploded perspective view when the mattress cover 10 is disassembled into the upper surface side cover 11 and the bottom surface side cover 12. The covers 11 and 12 can be joined by a fastener 13. The fastener 13 functions as an anti-stretching member as described above.

[0037] The upper surface side cover 11 in the state shown in FIG. 2(A) has a rectangular upper surface portion 11a that contacts the user at bedtime and a peripheral surface portion 11b composed of four rectangular side surfaces connected to the upper surface portion 11a. As a whole, it has a substantially rectangular parallelepiped shape with a space inside. An upper fastener member 13a is provided on the peripheral surface portion 11b.

[0038] The bottom surface side cover 12 in the state shown in FIG. 2(B) has a rectangular bottom surface portion 12a that contacts a horizontal floor, bed, etc. and a peripheral surface portion 12b composed of four rectangular side surfaces connected to the bottom surface portion 12a. As a whole, it has a substantially rectangular parallelepiped shape with a space inside. A lower fastener member 13b is provided on the peripheral surface portion 12b. When the upper fastener member 13a and the lower fastener member 13b are engaged, the fastener 13 in FIG. 1 is formed.

[0039] FIG. 3 is an exploded perspective view of the mattress cushion 20 housed in the mattress 1 shown in FIG. 1. The mattress cushion 20 can be divided into six cushion bodies 21 to 26 in the left-right direction and the length direction. In another view, the mattress cushion 20 is formed by arranging three cushion bodies 21 to 23 arranged in order in the length direction and three cushion bodies 24 to 26 arranged in order in the length direction side by side in the left-right direction.

[0040] The six cushion bodies 21 to 26 are formed of a resin filament three-dimensional conjugate body. The filament three-dimensional conjugate body is an elastic member obtained by three-dimensionally fusing and bonding molten filaments of a thermoplastic resin. In the manufacturing process of the filament three-dimensional conjugate body, molten thermoplastic resin is extruded vertically downward from a plurality of horizontally arranged nozzles. Thereby, a molten filament having a diameter of around 1 mm in cross section is dropped into cooling water, and a loop is formed by the buoyancy of the water. At the same time, the plurality of loop-formed molten filaments are three-dimensionally fused and bonded to obtain a filament three-dimensional conjugate body. At this time, by regulating the thickness and width of the group of molten filaments extruded from the plurality of nozzles with a chute (metal plate), a take-up machine (rollers, conveyors), etc., a smooth surface layer with a higher filament density at both ends in the thickness direction and both ends in the width direction than at the central part in the thickness direction can be formed. As such a method for manufacturing a filament three-dimensional conjugate body, the method disclosed in Patent Document 1 or the like can be adopted.

[0041] The thickness (vertical dimension) of the filament three-dimensional conjugate body is preferably in the range of 10 to 25 cm. Also, in the filament three-dimensional conjugate body, the filament diameter (diameter of the cross section) is preferably in the range of 0.5 to 2 mm, and the bulk density is preferably in the range of 30 to 150 kg / m 3 ³.

[0042] When the filament diameter in the filament three-dimensional conjugate body is less than 0.5 mm, the water drainage and drying time after washing become long. Conversely, when the filament diameter exceeds 2 mm, the soft feel of the filament three-dimensional conjugate body is likely to be lost. When the bulk density of the filament three-dimensional conjugate body is less than 30 kg / m 3 ³, the filament three-dimensional conjugate body itself is likely to be deformed in the length direction, and elliptical grooves and depressions are likely to occur on the surface of the mattress. Conversely, when the bulk density exceeds 150 kg / m 3 ³, the filament three-dimensional conjugate body becomes heavy and difficult to transport.

[0043] Incidentally, the bulk density of the filament three-dimensional aggregate can be measured, for example, by a measuring method using a rectangular parallelepiped-shaped measurement sample. In this measuring method, first, the mass W (kg) of the measurement sample and the sizes (m) of the measurement sample in each direction (longitudinal direction, lateral direction, and height direction) are measured. Also, by multiplying the sizes (m) of the measurement sample in each direction (longitudinal direction, lateral direction, height direction), the volume V (m 3 ) of the measurement sample is calculated. The bulk density (kg / m 3 ) is calculated by dividing the mass W (kg) of the measurement sample by the volume V (m 3 ) of the measurement sample.

[0044] On the six cushion bodies 21 to 26, smooth surface layers are respectively formed on the contact surfaces between the cushion bodies adjacent in the left-right direction, that is, the contact surfaces 21f, 24f between the cushion body 21 and the cushion body 24, the contact surfaces 22f, 25f between the cushion body 22 and the cushion body 25, and the contact surfaces 23f, 26f between the cushion body 23 and the cushion body 26. This smooth surface layer is a layer from the surface of the cushion body to a depth of 2 mm, has a higher bulk density than the inside thereof, and is a layer in which the cut ends (cut openings) of the filaments do not protrude outward from the surface. Incidentally, each of the above contact surfaces 21f to 26f is a surface parallel to the up-down direction (thickness direction) and orthogonal to the left-right direction.

[0045] The smooth surface layer is formed to prevent the end portions of the filaments (cut ends of the filaments or loop protrusions of the filaments) of one cushion body from entering into the filaments of the other cushion body at the contact surfaces between the adjacent cushion bodies, and it is preferable that the filaments are fused (bonded) at a high density so that the free filaments do not exist as protrusions.

[0046] As a method for forming a smooth surface layer, for example, there is a method of manufacturing a filament three-dimensional conjugate (network structure) using a chute described in Patent Document 1 and simultaneously forming a smooth surface layer on the surface layer (hereinafter, may be referred to as the "first method"), or a method of forming a filament three-dimensional conjugate and then cutting it into a predetermined size and then forming it by pressing while heating and melting the cut surface (hereinafter, may be referred to as the "second method").

[0047] If the density (porosity) of the smooth surface layer becomes too low, the air permeability (good air passage) of the filament three-dimensional conjugate is impaired and the repulsive force increases significantly. Therefore, the porosity of the smooth surface layer (the volume of air per unit volume) is preferably 30% or more and 85% or less. When the porosity is less than 30%, there is a concern that the air permeability may decrease and the repulsive force may become too high. On the other hand, when the porosity exceeds 85%, there is a concern that there will be many free (existing alone) filaments and the frictional force with adjacent cushion bodies will become too high.

[0048] Regarding the smoothness, it is sufficient if the ends of the filaments of one cushion body can be prevented from entering the interior of the filaments of the other cushion body at the contact surface of adjacent cushion bodies. As long as the porosity of the smooth surface layer is in the range of 30% or more and 85% or less, the smoothness obtained by pressing with a plate or a roller while melting the surface layer of the filament three-dimensional conjugate may be sufficient.

[0049] In this embodiment, an embodiment in which a smooth surface layer is formed only on the contact surfaces 21f to 26f of the cushion bodies adjacent to each other in the left-right direction among all the surfaces of each of the cushion bodies 21 to 26 is illustrated, but a smooth surface layer may be formed on all the surfaces of each of the cushion bodies 21 to 26. By smoothing all the surfaces, the upper surface of the mattress cushion 20 becomes smooth, improving the comfort, and it is also possible to smoothly take in and out from the mattress cover 10.

[0050] According to the first method described above, it is possible to form a smooth surface layer on the surface layer while manufacturing the filament three-dimensional conjugate. On the other hand, with respect to the cut surface generated by cutting the manufactured filament three-dimensional conjugate, it is possible to form a smooth surface layer by the second method.

[0051] As an apparatus that enables the formation of a smooth surface layer by the second method, for example, there is a cut surface smoothing apparatus Xa shown in FIG. 4. The cut surface smoothing apparatus Xa is an apparatus that performs a process of smoothing the cut surface FL1 of the filament three-dimensional conjugate FL cut to a predetermined size in the previous process.

[0052] As shown in this figure, each roller R is provided so as to face left and right on both the left and right sides of the conveyor C, and is rotatably installed with its central axis extending vertically as a rotation axis. The outer surface of one of the left and right rollers R contacts one cut surface FL1 of the filament three-dimensional conjugate FL conveyed by the conveyor C, and the outer surface of the other roller R is arranged to contact the other cut surface FL1. The distance between the outer surfaces of each roller R is set to be slightly smaller than the distance between both cut surfaces FL1 of the filament three-dimensional conjugate FL.

[0053] Inside each roller R, a heater H for heating the roller R is arranged. The heater H employs, for example, a halogen heater, and heats the roller R so that the temperature of at least the outer surface of the roller R becomes equal to or higher than the melting point of the filament three-dimensional conjugate FL. In the range not departing from the gist of the present invention, the specific form of the heater H is not particularly limited, and for example, it may be one that outputs hot air or one by IH (Induction Heating). Further, the heater H may be one that heats the roller R from the outside of the roller R.

[0054] When the filament three-dimensional conjugate body FL conveyed by the conveyor C passes through the position where it is sandwiched between the rollers R, each roller R rotates in the direction indicated by the dashed arrow in FIG. 5 due to the force received from the cut surface FL1. That is, each roller R rotates in the same direction as the conveying direction of the conveyor C while hitting the cut surface FL1 (that is, so that the traveling directions at the contact points are the same). Incidentally, a driving device such as a motor for rotationally driving the roller R may be provided, and the driving device may rotate the roller R in accordance with the conveying speed of the filament three-dimensional conjugate body FL.

[0055] Since the distance between the outer surfaces of the rollers R is slightly smaller than the distance between the two cut surfaces FL1 of the filament three-dimensional conjugate body FL, each cut surface FL1 advances in the conveying direction while being slightly pressed by each roller R. At this time, since the outer surface of each roller R is at a high temperature equal to or higher than the melting point of the filament three-dimensional conjugate body FL, each cut surface FL1 will be smoothed. When the entire filament three-dimensional conjugate body FL has passed through the position where it is sandwiched between the rollers R, the entire cut surface FL1 will be smoothed. In this way, it is possible to obtain a filament three-dimensional conjugate body FL in which the cut surfaces FL1 on both the left and right sides are smoothed.

[0056] Here, FIG. 5 shows an example of an external view (photo) of the cut surface FL1 before smoothing, and FIG. 6 shows an example of an external view (photo) of the cut surface FL1 after smoothing. Note that in FIG. 5, a view seen from a direction substantially orthogonal to the cut surface FL1 is shown. Also in FIG. 6, views seen from slightly different directions are shown on the left and right respectively.

[0057] As shown in Fig. 5, the cut surface FL1 before smoothing is in a state with prominent non-uniformity. In particular, due to the cutting of the loop shape of the filaments forming the filament three-dimensional conjugate FL by the cutter, the exposure of the ends of the filaments can be seen sporadically. On the other hand, in the cut surface FL1 shown in Fig. 6, the exposed ends of the filaments and the like are melted and then pressed by the roller R, and are fused to the neighboring filaments or deformed in the pressing direction, and are smoother compared to the cut surface FL1 shown in Fig. 5. Also, in the cut surface FL1, as a result of the entire filament being heated and melted and pressed by the roller R, it is smoothed. Thereby, the formation of the smooth surface layer by the second method is achieved.

[0058] In addition, as a specific method for forming the smooth surface layer by the second method, it is not limited to the method using the roller as described above. For example, as shown in Fig. 7, a heated flat plate 30 may be pressed against the cut surface (for example, the contact surfaces 21f, 24f) of the filament three-dimensional conjugate (for example, the cushion bodies 21, 24) in a direction perpendicular to the cut surface to form a smooth surface on the cut surface. As the heating means of the flat plate 30, in addition to using a halogen heater, high-frequency induction heating (IH) that heats using electromagnetic induction, or an ultrasonic plastic welder (manufactured by Ultrasonic Industry Co., Ltd.) that generates heat at the interface by applying ultrasonic vibration to the thermoplastic resin may be used. Although the second method is exemplified as a method for reducing the contact friction force of the cut surface that becomes the contact surface, it is not limited to this method as long as it is a method capable of reducing the contact friction force of the cut surface.

[0059] As a cutting device for cutting the filament three-dimensional conjugate with a blade, a high-speed cutting machine such as a circular saw can be mentioned. However, since the filament three-dimensional conjugate has a high porosity (80 - 95%) and the diameter of each filament is around 1 mm and is flexible, when the filament receives a compressive force or an impact force from the rotating teeth during the cutting of the filament three-dimensional conjugate, the filament easily deforms in the direction of escaping from the rotating teeth, and the filament is cut in a state where it has deformed in the direction of escaping from the rotating teeth.

[0060] When the filaments cut in the deformed state attempt to return to their pre-deformed state after the compressive force and impact force by the rotating teeth are removed, the return distances vary for each filament, resulting in an uneven cut surface. As a result, when viewing the virtual plane formed by connecting the cutting points of the filaments as the cutting surface of the filament three-dimensional aggregate, irregularities of about 5 to 10 mm occur on the cutting surface. When the irregularities exceed 5 mm, the cut ends of some filaments on the cutting surface of the filament three-dimensional aggregate penetrate into the adjacent filament three-dimensional aggregate, and the contact frictional force increases due to the generation of an engagement force.

[0061] In view of the above problems, as another method (the third method) for reducing the irregularities (contact frictional force) of the cutting surface, for example, a method of cutting using a circular saw with the filament three-dimensional aggregate cooled to a temperature at which its elasticity does not decrease, and a method of cutting using a circular saw with the filament three-dimensional aggregate compressed in the thickness direction (a state in which the filaments are difficult to move during cutting) can be mentioned. Also, as another method, there is a method of cutting using a circular saw with the peripheral speed of the rotating teeth of the circular saw increased. In this case, it is preferable that the peripheral speed of the rotating teeth be 50 m / sec or more. Also, as another method, there is a method of cutting using a circular saw with the compressive force applied from the rotating teeth to the filament three-dimensional aggregate reduced to reduce the deformation amount of the filament three-dimensional aggregate.

[0062] When using a filament three-dimensional aggregate with a repulsive force of 100 N or more and 200 N or less, it is preferable that the force applied from the tooth tip to the filament three-dimensional aggregate be 100 N or less, and it is preferable that the pressure applied from the rotating teeth to the filament three-dimensional aggregate be 5,000,000 pascals or less. Thereby, since the amplitude of the vibration generated in one of the adjacent filament three-dimensional aggregates becomes small at the contact surface, the vibration is less likely to be transmitted to the other filament three-dimensional aggregate. Also, as the smoothness index of the cutting surface, it is preferably 0 mm or more and 3 mm or less, and more preferably 0 mm or more and 1 mm or less.

[0063] In the present invention, the smoothness index of the cut surface of the cushion body can be measured by the following method. First, using two metal plates α with a plurality of 5 mm long metal needles fixed on the surface at 5 cm intervals, sandwich the cushion body in the thickness direction (the direction parallel to the cut surface) and fix it (the state where the metal needles of each metal plate α pierce the cushion body). In this state, a metal plate β having a pressing surface with the same shape and area as the cut surface is arranged so that the pressing surface faces the cut surface, and this metal plate β is translated parallel to the cut surface. In this way, the moving distance of the metal plate β from the time when the cut surface is pressed so that a pressure of 100 Pa is applied in the direction perpendicular to the cut surface to the time when the cut surface is pressed so that a pressure of 500 Pa is applied in the same direction is measured, and this measured moving distance is taken as the smoothness index. Note that the smaller the number of filaments protruding outward on the cut surface and the shorter the length of the filaments, the smaller the smoothness index of the cut surface tends to be, and it can be said that the degree of smoothness of the cut surface is high. In order to reduce the contact friction force of the cut surface, a cover covering the cut surface may be provided. By reducing the contact friction force of the cut surface, it becomes easier to put in and take out the mattress cover.

[0064] FIG. 8 is a conceptual diagram showing a state when the mattress 1 according to the first embodiment is used. FIG. 9 is a conceptual diagram showing a state in which vibration is blocked when the mattress 1 according to the first embodiment is used. In FIG. 9, the cushion body 21 and the cushion body 24 are adjacent to each other, and the state when a load W is applied to the cushion body 21 is shown on the right side, and the state when no load W is applied is shown on the left side.

[0065] When the user on the left side in FIG. 8 makes a turning-over motion, an up-and-down motion (vibration) occurs in the cushion body 21. However, since the contact surface 21f of the cushion body 21 and the contact surface 24f of the cushion body 24 are smoothed and the frictional force (binding force) is low, the transmission of the up-and-down motion (vibration) to the cushion body 24 is suppressed. As a result, the effect that the vibration is less likely to be transmitted to the user on the right side is obtained. Similarly, the vibration caused by the turning-over motion of the user on the right side is less likely to be transmitted to the user on the left side.

[0066] As described above, the mattress 1 has a mattress cushion 20, and is a mattress on which a plurality of people can lie horizontally in the left - right direction on the mattress cushion 20. The mattress cushion 20 includes a plurality of cushion bodies 21 - 26 that are separable in the left - right direction. In the mattress 1, each of the plurality of cushion bodies 21 - 26 is formed of a filament three - dimensional conjugate body composed of a plurality of filaments, and has contact surfaces 21f - 26f that contact other adjacent cushion bodies. Further, in the mattress 1, the ends of the filaments (the cut ends of the filaments and the loop protrusions of the filaments) of each of the plurality of cushion bodies 21 - 26 do not enter into other adjacent cushion bodies (that is, inside the contact surfaces of other adjacent cushion bodies).

[0067] Therefore, according to the mattress 1, at the contact surfaces 21f - 26f of the cushion bodies adjacent in the left - right direction, the contact frictional force generated by the ends of the filaments of one cushion body entering into the filaments of the other cushion body can be reduced. Thus, it is possible to suppress the vibration during turning over by one user from being transmitted to the other user. In the mattress 1, for each of the plurality of cushion bodies 21 - 26, in all regions of the contact surfaces 21f - 26f, the ends of the filaments do not protrude outside the contact surfaces. Therefore, it is surely prevented that the ends of the filaments enter into other adjacent cushion bodies.

[0068] Also, in the mattress 1, the resilience of each of the plurality of cushion bodies 21 - 26 is 100 N or more and 200 N or less, and the contact frictional force at the contact surfaces 21f - 26f between adjacent cushion bodies is preferably more than 0 N and less than 50 N. In this way, since the contact frictional force is less than 50 N, by using cushion bodies with a resilience of 100 N or more and 200 N or less, the amplitude of vibration is significantly attenuated at the contact surface. Therefore, it is possible to further suppress the vibration during turning over by one user from being transmitted to the other user.

[0069] Further, each of the plurality of cushion bodies 21 to 26 has a smooth surface layer on the contact surfaces 21f to 26f. Therefore, since there are no cut ends (cuts) of the filaments on the contact surfaces 21f to 26f, not only the static contact friction force but also the dynamic contact friction force can be reduced. Thus, even when vibrations with a large amplitude occur, it becomes difficult for the vibrations to be transmitted on the contact surfaces 21f to 26f.

[0070] 2. Second Embodiment Next, the second embodiment will be described. The second embodiment is basically the same as the first embodiment except that recesses, which will be described later, are formed on the contact surfaces 21f to 26f of each of the cushion bodies 21 to 26. In the second embodiment, the one corresponding to the cushion body 21 of the first embodiment is the cushion body 121, and the one corresponding to the cushion body 24 of the first embodiment is the cushion body 124.

[0071] FIG. 10 shows one method of forming a smooth surface layer by the second method and is an example of the method adopted in the second embodiment. In FIG. 10, the processing states for two cushion bodies 121 and 124 are shown, but the same processing is also performed on the remaining four cushion bodies (the cushion bodies corresponding to the cushion bodies 22, 23, 25, and 26 of the first embodiment).

[0072] As shown in FIG. 10, the cut surfaces (contact surfaces 121f, 123f) of the cushion bodies 121 and 124 are pressed by a heated roller 130. As a result, the cut surfaces are smoothed and densified simultaneously as the entire filaments are heated and melted and pressed by the roller 130, and a smooth surface layer is formed.

[0073] In the roller 130, a crown is formed on the roller surface that contacts the cutting surface. That is, the diameter dimension of the roller 130 with respect to the rotation axis increases toward the inside from both ends in the rotation axis direction. The method of heating the roller 130 may be the same as, for example, the method of heating the flat plate 30 described above. By pressing the cutting surface with the roller surface having such a crown, a concave portion that is recessed inward can be formed on the cutting surface.

[0074] FIG. 11 is a conceptual diagram showing a state when the cushion bodies 121 and 124 according to the second embodiment are used, and FIG. 12 is a conceptual diagram showing a state in which vibration is blocked when the cushion bodies 121 and 122 according to the second embodiment are used. In FIG. 12, the cushion body 121 and the cushion body 124 are adjacent to each other, and a state in which a load W is applied to the cushion body 121 is shown on the right side, and a state when no load W is applied is shown on the left side.

[0075] With the turning-over motion of the user on the left side in FIG. 11, vertical motion (vibration) occurs in the cushion body 121. However, since the contact surface 121f of the cushion body 121 and the contact surface 124f of the cushion body 124 are smoothed in a concave shape and the frictional force (engagement force) is almost eliminated, the transmission of the vertical motion (vibration) to the cushion body 124 is suppressed as much as possible. As a result, an effect is obtained in which the vibration is less likely to be transmitted to the user on the right side. Similarly, the vibration caused by the turning-over motion of the user on the right side is less likely to be transmitted to the user on the left side.

[0076] 3. Third Embodiment FIG. 13 is a perspective view of a mattress 200 according to the third embodiment. FIG. 14 is a plan view of the mattress 200. Note that the up-down, left-right, and front-back directions regarding the mattress 200 are as shown in FIG. 13. Also, in FIGS. 13 and 14, for easy understanding of the internal configuration of the mattress 200, the schematic positions of the respective cushion bodies Q11 to Q66 are shown by broken lines.

[0077] The mattress 200 includes a mattress cover 210 that covers the entire outer surface thereof, and a mattress cushion 220 formed of a filament three-dimensional conjugate body accommodated therein. The mattress 200 as a whole has a rectangular parallelepiped shape having sides in the front-back direction (length direction), left-right direction, and up-down direction (thickness direction). The left-right dimension is slightly smaller than the front-back dimension, and the up-down dimension is sufficiently smaller than the left-right dimension.

[0078] The mattress cushion 220 is composed of a total of 36 cushion bodies Q11 to Q66 that are divided into six parts in the left-right direction and six parts in the length direction. The mattress cushion 220 has a size that allows multiple people to lie side by side horizontally, but it can also be used by a single person lying horizontally.

[0079] Each of the 36 cushion bodies Q11 to Q66 has a rectangular parallelepiped shape, and a smooth surface layer is formed on all of the outer surfaces of each cushion body Q11 to Q66. This makes it smooth to put in and take out from the mattress cover 210 and suppresses the influence of friction with adjacent cushion bodies, so that independent up-and-down movement is possible. In each of the cushion bodies Q11 to Q66, a smooth surface layer may be formed only on the contact surface with an adjacent cushion body.

[0080] The mattress cover 210 has an upper surface side cover 210a, a bottom surface side cover 210b, and a fastener 213. With the mattress cushion 220 placed inside the upper surface side cover 210a and the bottom surface side cover 210b, the upper surface side cover 210a and the bottom surface side cover 210b are joined by the fastener 213.

[0081] The fastener 213 is configured to be less likely to stretch compared to other parts of the mattress cover 210, and serves to prevent the peripheral length of the mattress cover 210 from stretching (serves as an elongation prevention member). The fastener 213 is provided so as to have a substantially constant up-down position (height) and go around the outer peripheral surface of the mattress cover 210 when viewed from above.

[0082] In the mattress 200, the rectangular parallelepiped cushion bodies Q11 to Q66 having the same shape are accommodated in the mattress cover 210. As an application example of the mattress 200, two or more types of cushion bodies having at least one of different resilience and shape can be used. Thereby, since the cushion body of the mattress can be easily changed according to the position of the bed, the environment in which it is used, the physical condition of the user, or the function that the user wants to use, a comfortable sleeping environment can be provided under various changing conditions. Details of such application examples will be described later.

[0083] FIG. 15 is a perspective view of a mattress 290 according to a modification of the third embodiment. The mattress 290 has a structure in which an overlay mattress 270 is placed on the upper surface of the mattress 200 shown in FIG. 13. The overlay mattress 270 includes a mattress cover 210C that covers the entire outer surface thereof, and a mattress cushion 280 formed of a single filament three-dimensional conjugate body accommodated therein.

[0084] By placing the overlay mattress 270, it is possible to prevent a part of the body from falling into the gap between adjacent cushion bodies. The thickness of the mattress cushion 280 is preferably 10 mm or more and 50 mm or less. When the thickness is less than 10 mm, it is difficult to obtain the effect of suppressing the fall, and when it exceeds 50 mm, it is difficult to obtain the effect of dividing each cushion body of the mattress 200.

[0085] FIG. 16 is a perspective view showing the shapes of cushion bodies that can be used as application examples of the mattress 200 according to the third embodiment. Each of the various cushion bodies shown in FIG. 16 can be arbitrarily selected and used as each of the cushion bodies Q11 to Q66 in the mattress 200.

[0086] FIG. 16(a) represents a rectangular parallelepiped cushion body Da. By preparing in advance a plurality of types of cushion bodies Da having different resilience, it is possible to select a cushion body having an optimal resilience for each part of the body.

[0087] Figure 16(b) shows a rectangular parallelepiped-shaped cushion body Db with a two-layer structure. The cushion body Db is configured by arranging a highly resilient upper cushion body Dba and an ultra-highly resilient lower cushion body Dbb vertically, so that it can be used as a cushion body for sitting upright with extremely high resilience and little sinking even when sitting on a mattress without impairing body pressure dispersion.

[0088] Figure 16(c) shows a cushion body Dc with one end in the front-rear direction of a rectangular parallelepiped shape being raised. Even when there is no headboard provided on the bed, by arranging the cushion body Dc at the front end in the front-rear direction of the mattress cushion 220, an effect of preventing the pillow from slipping off can be obtained.

[0089] Figure 16(d) shows a cushion body Dd with one end in the left-right direction of a rectangular parallelepiped shape being raised. Even when there is no handrail, wall, etc. on the side of the bed, by arranging the cushion body Dd at the end in the left-right direction of the mattress cushion 220, an effect of preventing the futon from slipping off can be obtained.

[0090] Figure 16(e) shows a cushion body De (a modified example of the cushion body Dd) with one end in the left-right direction of a rectangular parallelepiped shape being raised. The cushion body De has an inclination angle of 90 degrees with respect to the non-raised part of the raised part, and at the same time, the corners of the raised part are rounded. By using the cushion body De, not only can the effect of preventing the futon from slipping off be achieved, but it is also possible to easily pull up the slipped-off futon.

[0091] Figure 16(f) shows a cushion body Df with one end in the front-back direction and the left-right direction of a rectangular parallelepiped shape raised. By installing the cushion body Df at the corner on the head side of the mattress (the front end of the mattress cushion 220), it can be used as a place to put small items such as smartphones, medicines, or watches that are necessary at bedtime. Note that not only the cushion body Df, but also in other cushion bodies, in order to prevent smartphones, plastic bottle drinks, etc. from falling or tipping over, a depression (holder) for storing smartphones and plastic bottles may be formed on the upper surface of the cushion body.

[0092] Figure 17 shows a specific application example of the mattress 200 according to the third embodiment, which is a conceptual diagram when viewed from the front (head direction). Figure 18 is a conceptual diagram when the specific application example of the mattress 200 shown in Figure 17 is viewed from the right side (right direction). In the mattresses shown in Figures 17 and 18, the installation of the overlay mattress 270 is omitted, and a mattress cover 210 that conforms to the shape of the mattress cushion 220 is adopted.

[0093] In the mattresses shown in Figures 17 and 18, the four cushion bodies Q21, Q31, Q41, Q51 shown in Figure 13 are replaced with a cushion body Dc (Figure 16(c)) in which one end in the front-back direction of a rectangular parallelepiped-shaped cushion body Da is raised, and the three cushion bodies Q62 to Q64 and the three cushion bodies Q12 to Q14 are replaced with a two-layer rectangular parallelepiped-shaped cushion body Db (Figure 16(b)) from a rectangular parallelepiped-shaped cushion body Da, and the two cushion bodies Q65, Q66 and the two cushion bodies Q15, Q16 are replaced with a cushion body Dd (Figure 16(d)) in which one end in the left-right direction of a rectangular parallelepiped-shaped cushion body Da is raised.

[0094] FIG. 19 is a conceptual diagram of a cushion body formed of a filament three-dimensional composite body in which an electronic component having a communication function (hereinafter sometimes referred to as an IoT module) that can be used as another application example of the mattress 200 according to the third embodiment is housed. Each of the various cushion bodies shown in FIG. 19 can be arbitrarily selected and used as each of the cushion bodies Q11 to Q66 in the mattress 200. Note that the cushion body shown in FIG. 19 may be appropriately combined with the configuration of the cushion body shown in FIG. 16 described above.

[0095] The IoT module housed in the cushion body includes a communication device, an electronic device connected to the communication device, and an internal battery. Further, the IoT module may be provided with an electrical wiring for supplying power from the outside as necessary.

[0096] Examples of the communication device included in the IoT module include short-range wireless communication devices such as Wi-fi, Bluetooth, and NFC. The short-range wireless communication device is connected to a host communication device (hereinafter sometimes simply referred to as a host device) such as a smartphone, and necessary data is transmitted and received. FIG. 20 shows a configuration example of a mattress system including an IoT module and a host device 300.

[0097] As the electronic device included in the IoT module, for example, information collection devices such as a temperature and humidity sensor, an acceleration sensor, a touch sensor, a switch, and a microphone are adopted. The IoT module 301 having such an information collection device transmits the collected information to the host device 300 as shown in FIG. 20.

[0098] Furthermore, as electronic devices included in the IoT module, for example, function-providing devices such as LED lighting, fans, speakers, heaters, humidifiers, thermal insulation shutters, germicidal ion generators, aroma generators, vibrators for massage, airbags for body pillows, airbags for calf lifting, airbags for bedridden patients, airbags for preventing bedsores by changing body positions, or airbags for waking up with up-and-down movements are adopted. The IoT module 302 having such function-providing devices receives data from the host device 300 through the communication device as shown in FIG. 20, and drives the function-providing devices based on the received data. That is to say, the above function-providing devices can also be said to be driving devices driven based on the data received by the communication device.

[0099] Incidentally, as a mattress for bedridden patients, an air mattress for bedridden patients composed of a plurality of airbags (sometimes called air cells) that can individually control pressure has been conventionally used. Since the cause of the occurrence and exacerbation of bedsores is poor blood circulation caused by the protruded specific parts such as the bones of bedridden patients who cannot turn over being compressed by the mattress for a long time, in order to remove the long-term compression, the pressure of each airbag is changed at intervals of about 10 minutes so that a high pressure is not applied to a specific part for a long time.

[0100] However, in the conventional air mattress for bedridden patients, due to the characteristics of the easily deformable airbag, when the internal pressure of the airbag becomes smaller than the internal pressure of the adjacent airbag, the contact area between the airbag with the smaller internal pressure and the bedridden patient becomes smaller, while the contact area between the adjacent airbag with the higher internal pressure and the bedridden patient becomes larger. As a result, there has been a problem that an area with a high pressure always occurs near the boundary of the airbag. In this regard, by providing a filament three-dimensional conjugate on the upper part of the airbag as in the present invention, the contact area with the bedridden patient remains unchanged, and the pressure distribution becomes distinct.

[0101] Note that a single cushion body may contain multiple electronic devices, or may contain both an IoT module 301 with an information collection device and an IoT 302 with a function providing device. Also, as shown in FIG. 20, outside the mattress 200, an external IoT module 303 such as an indoor air conditioner or an indoor lighting fixture is provided, and the external IoT module 303 is controlled by the host device 300.

[0102] FIG. 19(a) shows a rectangular parallelepiped cushion body Ua equipped with a temperature and humidity sensor Ma (IoT module 301) having a communication function inside. The temperature and humidity sensor Ma measures the temperature and humidity inside the mattress and transmits data to a host device 300 such as a smartphone. The host device 300 can send data to an external IoT module 303 such as an indoor air conditioner and control the external IoT module 303 according to a preset procedure.

[0103] FIG. 19(b) shows a rectangular parallelepiped cushion body Ub equipped with a touch sensor Mb (IoT module 301) having a communication function inside. Even in a completely dark bedroom, the touch sensor Mb can transmit data (the user's intention display) to the host device 300 just by the user touching it. The host device 300 that has received the data can send the data to an IoT module 302 having a function providing function of a blower fan or an external IoT module 303 such as an indoor lighting fixture according to a preset procedure, and can operate the IoT module 302 and the external IoT module 303.

[0104] FIG. 19(c) shows a rectangular parallelepiped cushion body Uc equipped with a blower fan Mc (IoT module 302) having a communication function inside. The rotation speed of the blower fan Mc is controlled according to the data sent from the host device 300.

[0105] Figure 19(d) shows a cushion body Ud with a rectangular parallelepiped shape having one end in the front-rear direction raised higher, equipped with an acceleration sensor Md (IoT module 301) having a communication function inside. By using the blower fan Mc, even in a completely dark bedroom, the user can send data (the user's intention indication) to the host device 300 just by pressing the acceleration sensor Md. The host device 300 that has received this data can send the data to an IoT module 302 having a function providing function such as a blower fan or an external IoT module 303 such as an indoor lighting lamp according to a preset procedure, and can operate the indoor lighting lamp, the blower fan, etc.

[0106] Figure 19(e) shows a cushion body Ue with a rectangular parallelepiped shape having one end in the front-rear direction raised higher, equipped with a microphone Me1 (IoT module 301) having a communication function inside and an LED lighting device Me2 (IoT module 302) having a communication function. By using the cushion body Ue, even in a completely dark bedroom, the user can send data (the user's intention indication) to the host device 300 just by speaking toward the microphone Me1. The host device 300 that has received the data can operate the LED lighting device Me2 etc. according to a preset procedure. Also, when the host device 300 is a device having a telephone function such as a smartphone, it may be possible for the user to make a phone call (have a conversation on the phone) with this voice when speaking toward the microphone Me1.

[0107] Figure 19(f) shows a rectangular parallelepiped-shaped cushion body Uf equipped with a plurality of cylindrical airbags Mf (IoT module 302) having a communication function inside. By using the cushion body Uf, by changing the internal pressure of the cylindrical airbag Mf, it is possible to change the repulsive force (ease of deformation) of the cushion body Uf without changing the height of the upper surface of the cushion body. A plurality of cylindrical airbags Mf are attached with an air pump Mfa capable of sending air into the airbag Mf or exhausting the air inside the airbag Mf, and the internal pressure of the airbag Mf can be changed according to the data sent from the host device 300.

[0108] Fig. 19(g) shows a rectangular parallelepiped two-layer cushion body Ug provided with an airbag Mg (IoT module 302) having a communication function at the lower part of the cushion body. By using the cushion body Ug, the height of the upper surface of the cushion body can be changed by changing the volume of the airbag Mg. The airbag Mg is provided with an air pump Mga capable of sending air into the airbag Mg or exhausting the air inside the airbag Mg, and the height of the airbag Mg can be changed according to the data sent from the host device 300. In Fig. 19(g), the state where air is sent into the airbag Mg is shown on the right side, and the state where no air is sent in is shown on the left side.

[0109] The mattress using the cushion body illustrated in Fig. 19 includes a cushion for mattress composed of a plurality of cushion bodies and a mattress cover for accommodating the cushion for mattress. The cushion for mattress includes a plurality of separable cushion bodies, and at least one or more of the plurality of cushion bodies include electronic components having a communication function. And in the mattress using the cushion body illustrated in Fig. 19, each of the plurality of cushion bodies is formed of a filament three-dimensional conjugate body composed of a plurality of filaments and has a contact surface that contacts another adjacent cushion body. Further, in the mattress, the ends of the filaments (the cut ends of the filaments and the loop protrusions of the filaments) of each of the plurality of cushion bodies do not enter into another adjacent cushion body (that is, inside the contact surface of another adjacent cushion body).

[0110] Therefore, according to the mattress, the contact friction force of the cushion body including the electronic component having the communication function can be reduced, so that it becomes easy for the user to fit the cushion body into a desired position. In the mattress using the cushion body illustrated in FIG. 19, each of the plurality of cushion bodies is configured such that the end portions of the filaments do not protrude outside the contact surface in all regions of the contact surface. Therefore, it is surely prevented that the end portions of the filaments enter into other adjacent cushion bodies.

[0111] Next, an order receiving system that can be used to receive an order for the mattress 200 according to the third embodiment by the order placer will be described. FIG. 21 is a block configuration diagram showing a configuration example of the order receiving system. The order receiving system 40 shown in FIG. 21 includes a mobile terminal 41 as an example of a communication terminal on the order placer side and a server 42 as an example of a communication terminal on the order receiving side. The mobile terminal 41 is a smartphone in FIG. 21 as an example, but may be a tablet, a mobile phone, or the like. Further, the communication terminal on the order placer side is not limited to the mobile terminal, and may be a PC (personal computer) or the like.

[0112] As shown in FIG. 21, the mobile terminal 41 includes a touch panel operation unit 41A, a communication module unit 41B, a control unit 41C, and a storage unit 41D. The touch panel operation unit 41A is included in the liquid crystal display unit and can operate the mobile terminal 41 when touched. The communication module unit 41B performs, for example, 4G communication (such as WiMAX2 or LTE-Advanced). The control unit 41C is, for example, a CPU and controls the entire mobile terminal 41. The storage unit 41D includes a ROM in which programs are stored, a RAM in which data is stored, and the like.

[0113] As shown in FIG. 21, the server 42 includes an Ethernet unit 42A, a control unit 42B, and a storage unit 42C. The Ethernet unit 42A is an Ethernet interface provided for performing IP communication with other devices (such as the mobile terminal 41). The control unit 42B is, for example, a CPU and controls the entire server 42. The storage unit 42C includes, for example, an HDD (hard disk drive) and a RAM.

[0114] A method for receiving an order for the mattress 200 using the order receiving system 40 having such a configuration will be described with reference to the flowchart shown in FIG. 22.

[0115] First, a cushion information input reception step (step S1) is executed. In this step, an input operation of cushion information is performed by operating the touch panel operation unit 41A by the order placer. Here, the order placer performs an input operation according to the Web screen displayed on the display unit of the mobile terminal 41 based on the data transmitted from the Ethernet unit 42A of the server 42 and received by the communication module unit 41B.

[0116] Here, FIG. 23 shows an example of the partition position numbers (numbers assigned to each position of different partitions) used when ordering the mattress 200. Here, the "partition" means a partition (block) in which one cushion body is arranged when viewed from above. The outer edge of the rectangular shape in FIG. 23 corresponds to the outer edge of the mattress 200 when viewed from above, and each position inside the rectangular shape corresponds to each position when the mattress 200 is viewed from above. In FIG. 23 (the same applies to FIGS. 25 to 29 described later), the approximate positions of the user and the pillow when lying horizontally on the mattress alone are shown by broken lines.

[0117] As shown in Fig. 23, for the mattress cushion 220, a total of 36 compartments are set, which are divided into six parts in the length direction and six parts in the left - right direction. Each cushion body will be arranged in these compartments. The cushion body corresponding to the compartment position number Bx (x is a number) shown in Fig. 23 corresponds to the cushion body Qx in the examples shown in Figs. 13 and 14. For example, the cushion body corresponding to the compartment position number B11 shown in Fig. 23 corresponds to the cushion body Q11 in the examples shown in Figs. 13 and 14.

[0118] Fig. 24 shows an example of a mattress order form used when ordering the mattress 200. As shown in Fig. 24, at the time of ordering, for each cushion body with different compartments, it is possible to specify and order the resilience level of the cushion body, the shape of the cushion body, and the presence or absence and type of IoT module provided in the cushion body. In the example shown in Fig. 24, for example, for the cushion body corresponding to the compartment position number B11, a cushion body with a resilience of "high", a shape of "rectangular parallelepiped", and no IoT module (that is, no IoT module is provided) is specified.

[0119] In this way, the cushion information input reception step is a process of receiving, at the communication terminal (mobile terminal 41) on the order - placer side, the input of cushion information, which is information about the cushion body for each compartment where each of the plurality of cushion bodies Q11 - Q66 is arranged. The cushion information includes information about the resilience of the cushion body for each compartment, information about the shape, and information about the electronic components having a communication function to be provided (information about the presence or absence and type of IoT module). In the mobile terminal 41, the input - operated cushion information is stored in the storage unit 41D, and the cushion information is received.

[0120] Next, the cushion information transmission step (step S2) is executed. In this step, in the mobile terminal 41, the cushion information stored in the storage unit 41D is transmitted to the server 42 by the communication module unit 41B.

[0121] Next, the cushion information reception step (step S3) is executed. In this step, the server 42 receives the cushion information transmitted from the communication module unit 41B by the Ethernet unit 42A. The received cushion information is stored in the storage unit 42C.

[0122] Next, the mattress cover model number determination step (step S4) is executed. In this step, in the server 42, the control unit 42B automatically determines the optimal model number of the mattress cover based on the cushion information stored in the storage unit 42C. More specifically, a unique model number is assigned in advance to each of a plurality of types of mattress covers having different shapes and the like. Then, considering the shape of each cushion body determined from the cushion information, the function by the IoT module, or the position where each cushion body is arranged, etc., an optimal one is selected from the plurality of types of mattress covers, and the model number of this selected mattress cover is determined as the optimal model number of the mattress cover.

[0123] In the process of selecting an optimal one from the plurality of types of mattress covers, for example, considering the shape of the cushion body to be adopted, the presence or absence of the airbag function by the IoT module, etc., it is considered whether it is a mattress cover whose shape and dimensions are suitable for the mattress cushion 220. Also, for example, considering the presence or absence of functions such as a microphone, LED lighting, and a blower fan by the IoT module, it is considered whether it is a mattress cover that can effectively utilize the function.

[0124] Next, the mattress information output step (step S5) is executed. In this step, in the server 42, information (mattress information) including the cushion information and the determined model number of the mattress cover is output.

[0125] The output of the mattress information is performed, for example, by transmitting it from the Ethernet unit 42A to an external manufacturing device. In this case, the manufacturing device can manufacture a mattress based on the received mattress information. Further, the output of the mattress information may be performed, for example, by displaying the mattress information on a display unit (not shown) included in the server 42. In this case, an operator can manufacture a mattress according to the displayed mattress information. The manufactured mattress is provided to the orderer, and thereby the orderer can use the ordered mattress.

[0126] Also, in the third embodiment, the compartment in which each cushion body is disposed has a rectangular shape, but the shape of the compartment is not particularly limited. For example, as shown in FIGS. 25 to 29, the compartment in which each cushion body is disposed may have a shape such as a rhombus, a triangle, or a hexagon. Note that, as the cushion body disposed in each compartment, a columnar body whose bottom surface is substantially congruent with that compartment is adopted.

[0127] In FIGS. 25 to 29, the rectangular outer edge corresponds to the outer edge of the mattress 200 in a top view, and the solid line inside the rectangle represents the boundary between adjacent compartments. FIG. 25 illustrates the arrangement form of each compartment when the shape of the compartment is mainly a rhombus, FIGS. 26 and 27 illustrate the arrangement form of each compartment when the shape of the compartment is mainly an equilateral triangle, and FIGS. 28 and 29 illustrate the arrangement form of each compartment when the shape of the compartment is mainly a regular hexagon.

[0128] As described above, the embodiments of the present invention have been described. However, the configuration of the present invention is not limited to the above embodiments, and various modifications can be made without departing from the gist of the invention. That is, the above embodiments should be considered as illustrative in all respects and not restrictive. The technical scope of the present invention is shown not by the description of the above embodiments but by the claims, and it should be understood that all modifications belonging to the meaning and scope equivalent to the claims are included.

Industrial Applicability

[0129] The present invention can be used for mattresses for various purposes.

Explanation of Signs

[0130] 1 Mattress 5 Mattresses 6 Mattresses 10 Mattress Covers 11 Upper Surface Side Cover 12 Bottom Surface Side Cover 13 Fastener 20 Cushions for Mattress 21 - 26 Cushion Bodies 21f - 26f Contact Surfaces 30 Flat Plate 40 Order Receiving System 41 Mobile Terminal 42 Server 50 Mattress Cover 51 Cushion Body 60 Mattress Cover 61, 62 Cushion Bodies 121, 124 Cushion Bodies 130 Roller 200 Mattresses 210 Mattress Cover 213 Fastener 220 Cushions for Mattress 270 Overlay Mattress 280 Cushions for Mattress 290 Mattresses 300 Host Device 301 IoT Module with Information Collection Device 302 IoT Module with Function Providing Device 303 External IoT Module 320, 420, 520, 620, 720 Cushions for Mattress C Conveyor Da - Df Cushion Bodies FL Filament 3D Conjugate FL1 Cutting Surface H Heater Ma Temperature and Humidity Sensor Mb Touch Sensor Mc Blower Fan Md Acceleration Sensor Me1 Microphone Me2 LED Lighting Equipment Mf Cylindrical Airbag Mfa Air Pump Mg Airbag Mga Air Pump Q11~Q66 Cushion Body R Roller Ua~Ug Cushion Body Xa Cutting Surface Smoothing Device

Claims

1. A mattress having a cushion for a mattress, wherein the cushion for the mattress includes a plurality of cushion bodies separable in a direction orthogonal to the thickness direction, each of the plurality of cushion bodies is formed of a filament three-dimensional conjugate body composed of a plurality of filaments, and a recess recessed inward is formed in a contact surface that contacts another adjacent cushion body, the mattress being characterized thereby.

2. The mattress according to claim 1, wherein the recess becomes deeper as it extends inward from both ends in the thickness direction of the contact surface.

3. The mattress according to claim 1, wherein the contact surface has a smooth surface layer.

4. A mattress on which a plurality of people can lie horizontally in the left-right direction on the cushion for the mattress, wherein the plurality of cushion bodies are separable in the left-right direction, and the contact surface is a surface that contacts another adjacent cushion body in the left-right direction, the mattress being characterized thereby according to claim 1.

5. A manufacturing method for each of the plurality of cushion bodies in the mattress according to any one of claims 1 to 4, wherein the method includes a pressing step of pressing the contact surface of each of the plurality of cushion bodies with a heated roller, and the manufacturing method is characterized in that the recess is formed by the pressing step due to a change in the diameter dimension of the roller with respect to the rotation axis in the rotation axis direction.

6. The manufacturing method according to claim 5, wherein the diameter dimension of the roller with respect to the rotation axis increases as it extends inward from both ends in the rotation axis direction.

7. The pressing step is a step of forming the recess and forming a smooth surface layer on the contact surface, the manufacturing method being characterized thereby according to claim 5.

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