Cushion body and manufacturing method of cushion body

Abstract

To provide a cushion body that can continue to provide excellent sleeping comfort to a user even when the user's body weight variation is large.SOLUTION: A cushion body 1 includes a lower layer member 14 and a higher layer member 13. The higher layer member 13 includes a third layer 33, a second layer 32, and a first layer 31. The higher layer member 13 and the lower layer member 14 include an uneven structure respectively. The lower layer member 14 includes a plurality of convex parts 15. The convex part 15 includes a top face 15a that comes in surface contact with the undersurface 33b. The hardness of a material constituting the first layer 31, and the hardness of a material constituting the third layer 33 are lower than the hardness of a material constituting the second layer 32, and the hardness of a material constituting the lower layer member 14. The impact resilience of a material constituting the first layer 31 and the impact resilience of a material constituting the third layer 33 are higher than the impact resilience of a material constituting the second layer 32 and the impact resilience of a material constituting the lower layer member 14.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a cushion body and a method for manufacturing the cushion body.

Background Art

[0002] Patent Document 1 describes a mattress composed of a lower layer, a middle layer laminated on the lower layer, and an upper layer laminated on the middle layer. The upper layer, middle layer, and lower layer are made of foam. On the upper layer, a plurality of convex portions and a plurality of concave portions are formed on the upper surface side where the user lies. In the middle layer, a plurality of convex portions having a frustum-of-a-square-pyramid shape and a plurality of concave portions are formed. In the lower layer, neither a plurality of convex portions nor a plurality of concave portions are formed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, when the user of the mattress is a child, it is necessary to consider that the amount of change in the user's weight over several years is larger than the amount of change in the user's weight when the user is an adult. In order to provide a comfortable sleeping experience for a child during a period when the weight is light, it is required that the mattress deforms moderately to suit the light body. Also, in order to provide a comfortable sleeping experience for a child during a period when the weight increases due to growth, an appropriate degree of resistance to compression is required to support the heavier body.

[0005] An object of the present disclosure is to provide a cushion body and a method for manufacturing the cushion body that can continuously provide a comfortable sleeping experience for the user even when the amount of change in the user's weight is large.

Means for Solving the Problems

[0006] The cushion body according to the present disclosure includes (1) a lower layer member and an upper layer member laminated on the lower layer member. The upper layer member has a third layer, a second layer laminated on the third layer, and a first layer laminated on the second layer. The upper layer member has an uneven structure extending from the first layer to the third layer. The lower layer member has an uneven structure that contacts the third layer. The lower layer member includes a plurality of convex portions that constitute the uneven structure of the lower layer member. The convex portion includes an upper surface that is in surface contact with the lower surface of the third layer. The hardness of the material constituting the first layer and the hardness of the material constituting the third layer are each lower than the hardness of the material constituting the second layer and the hardness of the material constituting the lower layer member. The resilience of the material constituting the first layer and the resilience of the material constituting the third layer are each higher than the resilience of the material constituting the second layer and the resilience of the material constituting the lower layer member.

[0007] In this cushion body, the hardness of the material constituting the first layer and the hardness of the material constituting the third layer are lower than the hardness of the material constituting the lower layer member. Therefore, for example, when a child with a light weight is the user, the first layer and the third layer have higher flexibility, so that the cushion body can be appropriately deformed to suit the user's body. Also, the hardness of the material constituting the second layer is higher than the hardness of the material constituting the first layer and the hardness of the material constituting the third layer. Therefore, the harder second layer can surely support the body of the user with a light weight. Also, the resilience of the material constituting the first layer and the resilience of the material constituting the third layer are each higher than the resilience of the material constituting the second layer and the resilience of the material constituting the lower layer member. Therefore, when the user places their body on the cushion body, it is possible to suppress the body from sinking too much. Also, when the user is a child, there is a concern that the amount of sweating will be more than that of an adult. In this cushion body, the lower layer member has an uneven structure that contacts the third layer. Therefore, since the air permeability inside the cushion body is enhanced, it is possible to suppress the stuffiness generated in the cushion body. Therefore, when a child with a light weight is the user, it is possible to provide the user with a comfortable sleeping experience.

[0008] In this cushion body, the hardness of the material constituting the lower layer member is higher than the hardness of the material constituting the first layer and the hardness of the material constituting the third layer. Therefore, for example, when a child with a heavier weight is the user, the lower layer member can surely support the user. Further, the lower layer member has an uneven structure that contacts the third layer. Therefore, when the user's body sinks the upper layer member, the lower layer member partially gives resistance to the user's body by the convex portions of the uneven structure. Thereby, it is possible to suppress the user from feeling a sudden change in hardness received from the lower layer member when the upper layer member sinks. Further, the convex portion includes an upper surface that is in surface contact with the lower surface of the third layer. Since the upper surface of the convex portion is in surface contact with the lower surface of the third layer, the upper layer member can be stably placed on the lower layer member. Thereby, since the lower layer member can be bonded to the third layer in a stable state, the lower layer member can be surely bonded to the third layer. The fact that it is possible to suppress the body from sinking too much when the user places the body on the cushion body and the fact that it is possible to suppress the stuffiness generated in the cushion body are common effects obtained even when a child with a heavier weight is the user for the reasons described above. Therefore, even when a child with a heavier weight is the user, a comfortable sleeping comfort can be provided to the user. As a result, even when the amount of change in the user's weight is large, a comfortable sleeping comfort can be continuously provided to the user.

[0009] (2) In the above (1), the lower surface of the first layer may be bonded to the upper surface of the second layer with an elastic adhesive. The lower surface of the second layer may be bonded to the upper surface of the third layer with an elastic adhesive. In this case, it is possible to adjust the hardness of the upper layer member according to the amount of the elastic adhesive. That is, the hardness of the upper layer member can be adjusted by adjusting the amount of the elastic adhesive between the first layer and the second layer and the amount of the elastic adhesive between the second layer and the third layer.

[0010] (3) In the above (1) or (2), the material constituting the first layer may be the same as the material constituting the third layer. In this case, by preparing one material, the first layer and the third layer can be manufactured. Therefore, the types of materials to be prepared can be reduced, and the manufacture of the cushion body can be easily performed.

[0011] (4) In any of the above (1) to (3), the material constituting the second layer may be the same as the material constituting the lower layer member. In this case, by preparing one material, the second layer and the lower layer member can be manufactured. Therefore, the types of materials to be prepared can be reduced, and the manufacture of the cushion body can be easily performed.

[0012] The method for manufacturing a cushion body according to the present disclosure includes: (5) a step of manufacturing a block body including a first layer, a second layer, and a third layer by laminating a plate-shaped second layer on the plate-shaped third layer and laminating a plate-shaped first layer on the second layer; a step of manufacturing an upper layer member having a concavo-convex structure by cutting the block body along a cutting line that meanders so as to reciprocate from the first layer to the third layer; a step of forming a concavo-convex structure on a plate-shaped lower layer member; and a step of attaching the concavo-convex structure of the lower layer member to the third layer. The hardness of the material constituting the first layer and the hardness of the material constituting the third layer are each lower than the hardness of the material constituting the second layer and the hardness of the material constituting the lower layer member. The resilience of the material constituting the first layer and the resilience of the material constituting the third layer are each higher than the resilience of the material constituting the second layer and the resilience of the material constituting the lower layer member.

[0013] In the method for manufacturing this cushion body, after producing a block body including a first layer, a second layer, and a third layer, an upper layer member having a concavo-convex structure is produced from the block body. Further, a lower layer member is prepared independently of the step of producing the upper layer member, and a concavo-convex structure is formed on the lower layer member. Therefore, since the concavo-convex structure can be formed on the single lower layer member, the concavo-convex structure can be easily formed on the lower layer member. Further, in order to form a concavo-convex structure on the upper layer member, the block body is cut along a meandering cutting line that reciprocates from the first layer to the third layer. Accordingly, convex portions constituting the concavo-convex structure are formed on the upper layer member. Thereby, when the user places the body on the cushion body, the touch feeling obtained by the user from the convex portions can be improved.

[0014] (6) In the above (5), the step of producing the block body may include a step of bonding the upper surface of the second layer to the lower surface of the first layer with an elastic adhesive, and a step of bonding the upper surface of the third layer to the lower surface of the second layer with an elastic adhesive. In each of the step of bonding the upper surface of the second layer and the step of bonding the upper surface of the third layer, the hardness of the upper layer member may be adjusted by adjusting the amount of the elastic adhesive. In this case, the hardness of the upper layer member can be adjusted by the amount of the elastic adhesive applied between the first layer and the second layer and the amount of the elastic adhesive applied between the second layer and the third layer.

[0015] (7) In the above (5) or (6), the step of forming the concavo-convex structure on the lower layer member may include the step of forming the upper surface of the convex portion by cutting each of the plurality of convex portions constituting the concavo-convex structure of the lower layer member along the lower surface of the third layer. In the step of attaching the lower layer member to the third layer, the surface of the third layer opposite to the second layer may be attached to the upper surface of the convex portion. In this case, since the upper surface of the convex portion is formed by cutting each of the plurality of convex portions along the lower surface of the third layer, the lower surface of the third layer can be brought into surface contact with the upper surface of the convex portion. By bringing the upper surface of the convex portion into surface contact with the lower surface of the third layer, the upper layer member can be stably placed on the lower layer member. As a result, the lower layer member can be attached to the third layer in a stable state, so that the lower layer member can be reliably attached to the third layer.

Effect of the Invention

[0016] According to the present disclosure, even when the amount of change in the user's body weight is large, it is possible to continue to provide the user with a comfortable sleeping experience.

Brief Description of the Drawings

[0017]

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Embodiments for Carrying Out the Invention

[0018] Hereinafter, embodiments of a cushion body and a method for manufacturing the cushion body according to the present disclosure will be described with reference to the drawings. In the description of the drawings, the same or corresponding elements are denoted by the same reference numerals, and redundant descriptions are omitted as appropriate. The drawings may be drawn with some parts simplified or exaggerated for ease of understanding, and the dimensional ratios and the like are not limited to those described in the drawings.

[0019] Figure 1 is a plan view of the cushion body 1. Figure 2 is an enlarged side view of a part of the cushion body 1. The cushion body 1 is used, for example, as a bedding such as a mattress, a futon, or a cushion. In the present embodiment, an example in which the cushion body 1 is a children's mattress will be described. The cushion body 1 is a children's bedding. For example, the age of the user of the cushion body 1 is 5 years old or more and 12 years old or less. The weight of a child increases from about 20 kg to about 45 kg between the ages of 5 and 12. The cushion body 1 according to the present embodiment is a mattress suitable for children whose weight increases from 20 kg to 45 kg. The cushion body 1 is used, for example, while being housed in a stain-proof cover. The cushion body 1 is made of a flexible material. The flexible material refers to a material having a softness that deforms when the body is placed thereon.

[0020] The cushion body 1 has, for example, an upper surface 1a against which a user's body is applied, and a lower surface 1b facing the side opposite to the upper surface 1a. As an example, unevenness including convex portions 11 and concave portions 12 is formed on the upper surface 1a, and the lower surface 1b is flat. The convex portions 11 and the concave portions 12 will be described in detail later.

[0021] The cushion body 1 has a short side 1c extending in a first direction D1 in plan view, and a long side 1d extending in a second direction D2 intersecting the first direction D1 in plan view. In the present embodiment, the second direction D2 is orthogonal to the first direction D1. In the present embodiment, the first direction D1 indicates the short side direction (width direction) of the cushion body 1, and the second direction D2 indicates the longitudinal direction of the cushion body 1. The length of the short side 1c is, for example, 970 mm or more and 990 mm or less. The length of the short side 1c is, for example, 980 mm. The length of the long side 1d is, for example, 1965 mm or more and 2005 mm or less. The length of the long side 1d is, for example, 1980 mm.

[0022] The cushion body 1 has a thickness in a third direction D3 which is a direction intersecting both the first direction D1 and the second direction D2. In the present embodiment, the third direction D3 is orthogonal to the first direction D1 and is also orthogonal to the second direction D2. The thickness of the cushion body 1 is, for example, 71 mm or more and 75 mm or less. The thickness of the cushion body 1 is, for example, 73 mm. The upper surface 1a extends in both the first direction D1 and the second direction D2. The lower surface 1b extends in both the first direction D1 and the second direction D2 and is spaced apart from the upper surface 1a in the third direction D3. In the following description, the direction from the lower surface 1b toward the upper surface 1a in the third direction D3 may be referred to as "up", "upper side" or "above", and the direction from the upper surface 1a toward the lower surface 1b in the third direction D3 may be referred to as "down", "lower side" or "below".

[0023] The cushion body 1 has, for example, a plurality of convex portions 11 protruding in the third direction D3 and a plurality of concave portions 12 recessed in the third direction D3. For example, the plurality of convex portions 11 are arranged along each of the first direction D1 and the second direction D2, and the plurality of concave portions 12 are arranged along each of the first direction D1 and the second direction D2. That is, the plurality of convex portions 11 and the plurality of concave portions 12 are arranged in a lattice pattern on the upper surface 1a of the cushion body 1.

[0024] As shown in FIG. 2, the plurality of convex portions 11 and the plurality of concave portions 12 exhibit a waveform shape on the upper surface 1a. The cushion body 1 includes an upper layer member 13 including the upper surface 1a and a lower layer member 14 including the lower surface 1b. The upper layer member 13 is laminated on the lower layer member 14. The upper layer member 13 has a plurality of layers laminated along the third direction D3. The upper layer member 13 has a third layer 33, a second layer 32 laminated on the third layer 33, and a first layer 31 laminated on the second layer 32.

[0025] The upper layer member 13 (the first layer 31, the second layer 32, and the third layer 33) supports the body of a child with a light weight (for example, a weight of 20 kg or more and 30 kg or less), and both the upper layer member 13 and the lower layer member 14 support the body of a child with a heavy weight (for example, a weight of 30 kg or more and 50 kg or less). The body of a child with a light weight is suppressed from sinking too much by the first layer 31 and supported by the second layer 32. The body of a child with a heavy weight is suppressed from sinking too much by the first layer 31 and the third layer 33 and supported by the lower layer member 14. The upper layer member 13 has an uneven structure constituted by the plurality of convex portions 11 and the plurality of concave portions 12. The top of the convex portion 11 is formed in the first layer 31. The bottom of the concave portion 12 is formed in the third layer 33. Thus, the uneven structure extends from the first layer 31 to the third layer 33.

[0026] The first layer 31 includes the top of the convex portion 11 and constitutes a part (upper part) of the convex portion 11. The first layer 31 included in each of the plurality of convex portions 11 is not connected to a different first layer 31. That is, the plurality of first layers 31 constituting the upper part of the convex portion 11 are independent of each other. The first layer 31 has an upper surface that constitutes a part of the upper surface 1a and a lower surface 31b facing the opposite side of the upper surface. The upper surface of the first layer 31 has a corrugated shape. The lower surface 31b is a flat surface. The length of the first layer 31 in the third direction D3 is, for example, 5 mm or more and 10 mm or less. The length of the first layer 31 in the third direction D3 is, for example, 9 mm.

[0027] The hardness of the material constituting the first layer 31 is lower than the hardness of the material constituting the second layer 32. The hardness of the material constituting the first layer 31 is lower than the hardness of the material constituting the lower layer member 14. The 40% hardness of the material constituting the first layer 31 is, for example, 120 N or more and 180 N or less. The 40% hardness of the material refers to the magnitude of the force required to crush a member having a predetermined thickness made of the material to 60% of the thickness of the member when no force is applied, by applying a force in the thickness direction to the member.

[0028] The resilience of the material constituting the first layer 31 is higher than the resilience of the material constituting the second layer 32. The resilience of the material constituting the first layer 31 is higher than the resilience of the material constituting the lower layer member 14. The resilience of the material constituting the first layer 31 is, for example, 50% or more and 70% or less. Thereby, since the topmost first layer 31 can provide high resilience, it is possible to suppress the body from sinking too much. The resilience of the material refers to the ratio of the height to which a steel ball rebounds and rises to the predetermined height when the steel ball is dropped onto a plate-like member made of the material from a predetermined height. The first layer 31 is constituted by, for example, HKI (high resilience urethane foam).

[0029] The second layer 32 is harder, has lower resilience, and is thinner than the first layer 31 and the third layer 33. The second layer 32 can reliably support the body of a light-weight child. The second layer 32 constitutes a part of the protrusion 11. The second layer 32 constitutes a central portion of the protrusion 11 in the third direction D3. The second layer 32 has a trapezoidal shape in a side view of the cushion body 1. The second layer 32 has an upper surface 32a facing the lower surface 31b and a lower surface 32b facing the opposite side to the upper surface 32a. The upper surface 32a is a flat surface. The lower surface 32b is a flat surface. The side surface of the second layer 32 is a curved surface. The length of the second layer 32 in the third direction D3 is, for example, 5 mm or more and 10 mm or less. The length of the second layer 32 in the third direction D3 is, for example, 9 mm. The 40% hardness of the material constituting the second layer 32 is, for example, 190 N or more and 250 N or less. The rebound resilience of the material constituting the second layer 32 is, for example, 35% or more and 50% or less. The second layer 32 is made of, for example, HKE (high hardness urethane foam).

[0030] The third layer 33 constitutes a part (the lowermost part) of the protrusion 11 and also includes the bottom of the recess 12. The third layer 33 has an upper surface 33a facing the lower surface 32b, and a lower surface 33b facing the opposite side to the upper surface 33a. The upper surface 33a is a flat surface. The lower surface 33b is a flat surface. The lower surface 33b constitutes the lower surface of the upper layer member 13. The length in the third direction D3 of the third layer 33 is, for example, 20 mm or more and 35 mm or less. The length in the third direction D3 of the third layer 33 is, for example, 28 mm.

[0031] The hardness of the material forming the third layer 33 is lower than the hardness of the material forming the second layer 32. The hardness of the material forming the third layer 33 is lower than the hardness of the material forming the lower member 14. The resilience of the material forming the third layer 33 is higher than the resilience of the material forming the second layer 32. The resilience of the material forming the third layer 33 is higher than the resilience of the material forming the lower member 14. Due to the resilience of the material forming the first layer 31 and the resilience of the material forming the third layer 33 being higher than the resilience of the second layer 32, the convex portion 11 is more likely to rebound. For example, the material forming the third layer 33 is the same as the material forming the first layer 31. However, the material forming the third layer 33 may be different from the material forming the first layer 31. The 40% hardness of the material forming the third layer 33 is, for example, 120 N or more and 180 N or less. The resilience of the material forming the third layer 33 is, for example, 50% or more and 70% or less. The third layer 33 is formed of, for example, HKI.

[0032] The upper member 13 has an elastic adhesive 34 for bonding the first layer 31 to the second layer 32 and an elastic adhesive 35 for bonding the second layer 32 to the third layer 33. The elastic adhesive 34 is interposed between the lower surface 31b of the first layer 31 and the upper surface 32a of the second layer 32. The hardness of the elastic adhesive 34 when cured is higher than the hardness of the material forming the first layer 31. The hardness of the elastic adhesive 34 when cured is higher than the hardness of the material forming the second layer 32. The elastic adhesive 34 is, for example, an adhesive with higher strength than a water-soluble adhesive. The elastic adhesive 34 is, for example, a hot melt adhesive. The hot melt adhesive is applied in a molten state at a high temperature. The molten hot melt adhesive solidifies when the temperature decreases. The hot melt adhesive exerts an adhesive action by solidifying.

[0033] The elastic adhesive 35 is interposed between the lower surface 32b of the second layer 32 and the upper surface 33a of the third layer 33. The hardness of the elastic adhesive 35 when cured is higher than the hardness of the material constituting the second layer 32. The hardness of the elastic adhesive 35 when cured is higher than the hardness of the material constituting the third layer 33. The elastic adhesive 35 is, for example, a hot melt adhesive. For example, the material constituting the elastic adhesive 35 is the same as the material constituting the elastic adhesive 34. However, the material constituting the elastic adhesive 35 may be different from the material constituting the elastic adhesive 34.

[0034] The hardness of the upper layer member 13 is contributed by each of the first layer 31, the second layer 32, the third layer 33, the elastic adhesive 34, and the elastic adhesive 35. The hardness of the upper layer member 13 is contributed by the hardness of the material constituting the first layer 31 and the weight (or thickness) of the first layer 31. The hardness of the upper layer member 13 is contributed by the hardness of the material constituting the second layer 32 and the weight (or thickness) of the second layer 32. The hardness of the upper layer member 13 is contributed by the hardness of the material constituting the third layer 33 and the weight (or thickness) of the third layer 33. The hardness of the upper layer member 13 is contributed by the hardness of the elastic adhesive 34 when cured and the weight (or thickness) of the elastic adhesive 34 of the upper layer member 13. The hardness of the upper layer member 13 is contributed by the hardness of the elastic adhesive 35 when cured and the weight (or thickness) of the elastic adhesive 35 of the upper layer member 13.

[0035] The hardness of the upper member 13 is adjusted, for example, by the weight of the elastic adhesive 34 and the weight of the elastic adhesive 35 respectively. When the weight of the elastic adhesive 34 or the weight of the elastic adhesive 35 increases, the hardness of the upper member 13 is increased. When the weight of the elastic adhesive 34 or the weight of the elastic adhesive 35 decreases, the hardness of the upper member 13 is decreased. The hardness of the upper member 13 may be adjusted by the thickness of the elastic adhesive 34 when cured and the thickness of the elastic adhesive 35 when cured respectively. When the thickness of the elastic adhesive 34 when cured or the thickness of the elastic adhesive 35 when cured increases, the hardness of the upper member 13 is increased. When the thickness of the elastic adhesive 34 when cured or the thickness of the elastic adhesive 35 when cured decreases, the hardness of the upper member 13 is decreased.

[0036] The lower member 14 has a single layer. For example, the material constituting the lower member 14 is the same as the material constituting the second layer 32. However, the material constituting the lower member 14 may be different from the material constituting the second layer 32. The 40% hardness of the material constituting the lower member 14 is, for example, 190 N or more and 250 N or less. The resilience of the material constituting the lower member 14 is, for example, 35% or more and 50% or less. The lower member 14 is constituted by, for example, HKE.

[0037] The lower member 14 has an upper surface 14a facing the lower surface 33b of the third layer 33. The lower surface of the lower member 14 facing the opposite side of the upper surface 14a constitutes the lower surface 1b. The length of the third layer 33 in the third direction D3 is, for example, 20 mm or more and 35 mm or less. The length of the third layer 33 in the third direction D3 is, for example, 27 mm.

[0038] The lower layer member 14 has a concavo-convex structure provided on the upper surface 14a. More specifically, the lower layer member 14 has, for example, a plurality of convex portions 15 protruding in the third direction D3 and a plurality of concave portions 16 recessed in the third direction D3. The concavo-convex structure of the lower layer member 14 is constituted by the plurality of convex portions 15 and the plurality of concave portions 16. For example, the plurality of convex portions 15 are arranged along each of the first direction D1 and the second direction D2, and the plurality of concave portions 16 are arranged along each of the first direction D1 and the second direction D2. That is, the plurality of convex portions 15 and the plurality of concave portions 16 are arranged in a lattice pattern on the upper surface 14a.

[0039] The convex portion 15 has an upper surface 15a facing the lower surface 33b. For example, the upper surface 15a is a flat surface. However, the upper surface 15a only needs to follow the lower surface 33b and does not have to be a flat surface. The upper surface 15a is in contact with the lower surface 33b. In this specification, "contact" includes both the case of direct contact and the case of indirect contact. Specifically, the upper surface 15a may be in direct contact with the lower surface 33b without sandwiching another member therebetween, or may be in contact with the lower surface 33b by sandwiching, for example, an adhesive therebetween. The upper surface 15a is in surface contact with the lower surface 33b.

[0040] "Surface contact" means that one of the two surfaces is in contact with the other surface along the other surface. The one surface and the other surface may be a plane or a curved surface. When the one surface is a plane, the other surface is a plane. When the one surface is a curved surface, the other surface is a curved surface, and the difference between the curvature of the one surface and the curvature of the other surface is equal to or less than a certain value. Since the upper surface 15a is in surface contact with the lower surface 33b, the concavo-convex structure of the lower layer member 14 is in contact with the third layer 33.

[0041] The recess 16 exhibits a part of a waveform shape. The convex portion 15 is arranged along the third direction D3 with the convex portion 11. The recess 16 is arranged along the third direction D3 with the recess 12. However, the convex portion 15 may not be arranged along the third direction D3 with the convex portion 11, and the recess 16 may not be arranged along the third direction D3 with the recess 12. Further, the convex portion 15 may be arranged along the third direction D3 with the recess 12, or the recess 16 may be arranged along the third direction D3 with the convex portion 11. Since the cushion body 1 is provided with the recess 16, the air permeability inside the cushion body 1 is improved. Since the cushion body 1 is provided with the recess 16, when the upper layer member 13 is crushed, the user receives a resistance force from the convex portion 15. The magnitude of the resistance force received by the user when the recess 16 is provided is smaller than when the recess 16 is not provided.

[0042] The cushion body 1 has an elastic adhesive 17 that bonds the upper layer member 13 to the lower layer member 14. The elastic adhesive 17 is interposed between the lower surface 33b of the third layer 33 and the upper surface 15a of the lower layer member 14. The hardness of the elastic adhesive 17 when cured is higher than the hardness of the material constituting the third layer 33. The hardness of the elastic adhesive 17 when cured is higher than the hardness of the material constituting the lower layer member 14. The elastic adhesive 17 is, for example, a hot melt adhesive. The material constituting the elastic adhesive 17 may be the same as the material constituting the elastic adhesive 34 and the material constituting the elastic adhesive 35. However, the material constituting the elastic adhesive 17 may be different from at least one of the material constituting the elastic adhesive 34 and the material constituting the elastic adhesive 35.

[0043] The hardness of the cushion body 1 is contributed by each of the upper layer member 13, the lower layer member 14, and the elastic adhesive 17. The hardness of the cushion body 1 is contributed by the hardness of the upper layer member 13 and the weight (or thickness) of the upper layer member 13. The hardness of the cushion body 1 is contributed by the hardness of the material constituting the lower layer member 14 and the weight (or thickness) of the lower layer member 14. The hardness of the cushion body 1 is contributed by the hardness of the elastic adhesive 17 when cured and the weight (or thickness) of the elastic adhesive 17.

[0044] The hardness of the cushion body 1 is adjusted, for example, by the weight of the elastic adhesive 17. When the weight of the elastic adhesive 17 increases, the hardness of the cushion body 1 is increased. When the weight of the elastic adhesive 17 decreases, the hardness of the cushion body 1 is decreased. The hardness of the cushion body 1 may be adjusted by the thickness of the elastic adhesive 17 when it is cured. When the thickness of the elastic adhesive 17 when it is cured increases, the hardness of the cushion body 1 is increased. When the thickness of the elastic adhesive 17 when it is cured decreases, the hardness of the cushion body 1 is decreased.

[0045] Thus, the cushion body 1 has an elastic adhesive 34 which is a first elastic adhesive, an elastic adhesive 35 which is a second elastic adhesive, and an elastic adhesive 17 which is a third elastic adhesive.

[0046] Next, the effects obtained from the cushion body 1 according to the present embodiment will be described. In this cushion body 1, the hardness of the material constituting the first layer 31 and the hardness of the material constituting the third layer 33 are lower than the hardness of the material constituting the lower layer member 14. For example, when a child with a light body weight is the user, the first layer 31 and the third layer 33 have higher flexibility, so that the cushion body 1 can be appropriately deformed to suit the user's body. Examples of children with a light body weight include lower grade elementary school children. The body weight of a child with a light body weight is, for example, 20 kg or more and 30 kg or less.

[0047] In addition, the hardness of the material constituting the second layer 32 is higher than the hardness of the material constituting the first layer 31 and the hardness of the material constituting the third layer 33. Therefore, the harder second layer 32 can reliably support the body of a user with a light body weight. Also, the resilience of the material constituting the first layer 31 and the resilience of the material constituting the third layer 33 are each higher than the resilience of the material constituting the second layer 32 and the resilience of the material constituting the lower layer member 14. Therefore, when the user places their body on the cushion body 1, the first layer 31 and the third layer 33 rebound, so that it is possible to prevent the body from sinking too much. Also, when the user is a child, there is concern that the amount of sweating will be greater than that of an adult. In this cushion body 1, the lower layer member 14 has an uneven structure that contacts the third layer 33. Therefore, since the air permeability inside the cushion body 1 is enhanced, it is possible to suppress the stuffiness that occurs in the cushion body 1. Therefore, when a child with a light body weight is the user, it is possible to provide the user with a comfortable sleeping experience.

[0048] In this cushion body 1, the hardness of the material constituting the lower layer member 14 is higher than the hardness of the material constituting the first layer 31 and the hardness of the material constituting the third layer 33. Therefore, for example, when a child with a heavier body weight is the user, the lower layer member 14 can reliably support the user. Examples of a child with a heavier body weight include, for example, upper grade elementary school children. The body weight of a child with a heavier body weight is, for example, 30 kg or more and 50 kg or less.

[0049] The effect of the cushion body 1 will be described in more detail with reference to FIG. 3. FIG. 3 is a graph showing the result of measuring the relationship between the sinking amount of the cushion body 1 and the stress caused by the cushion body 1. This measurement was performed in accordance with JIS K 6400-2 E method. The 40% hardness of the material constituting the first layer 31 of the cushion body 1 used in the measurement and the 40% hardness of the material constituting the third layer 33 are 150N. The resilience of the material constituting the first layer 31 and the resilience of the material constituting the third layer 33 are 50%. The 40% hardness of the material constituting the second layer 32 and the 40% hardness of the material constituting the lower layer member 14 are 220N. The resilience of the material constituting the second layer 32 and the resilience of the material constituting the lower layer member 14 are 40%.

[0050] The height from the lower surface 1b of the cushion body 1 to the top of the convex portion 11 (length in the third direction D3) is 73 mm. The height from the lower surface 1b to the bottom of the concave portion 12 is 46 mm. The height from the lower surface 1b to the upper surface 15a of the convex portion 15 is 27 mm. The height from the lower surface 1b to the bottom of the concave portion 16 is 15 mm. The height of the first layer 31 is 9 mm. The height of the second layer 32 is 9 mm. The height of the third layer 33 is 28 mm.

[0051] When a user places his / her body on the cushion body 1, the load applied to the user's waist area is approximately 46% of the body weight. When a user weighing approximately 21 kg places his / her body on the cushion body 1, a load of approximately 100 N is applied to the waist area. In FIG. 3, the amount of sinking corresponding to a stress of approximately 100 N is approximately 20 mm. As the amount of sinking increases from 20 mm to 25 mm, the increase in stress per unit amount of sinking decreases. As a result, the graph shows a bulging shape in the range of sinking amounts from 20 mm to 25 mm.

[0052] The fact that the graph exhibits such a bulging shape indicates that the cushion body 1 is dispersing the load. Particularly in areas where the stress is not high, the fact that the graph exhibits such a bulging shape indicates that the portion compressed by the load is soft and has appropriate rebound elasticity. That is, when a user applies a load of about 100 N, since the compressed portion is soft, the cushion body can be appropriately deformed to fit the body, and since the compressed portion has appropriate rebound elasticity, it indicates that the body can be prevented from sinking too much.

[0053] When the cushion body 1 sinks by 20 mm to 25 mm, the user's body mainly applies a load to and compresses the first layer 31, the second layer 32, and the third layer 33. Therefore, when a lower elementary school child is the user, the low hardness of the material constituting the first layer 31 and the low hardness of the material constituting the third layer 33 contribute to appropriately deforming the cushion body to fit the body. Also, when a lower elementary school child is the user, the high rebound elasticity of the material constituting the first layer 31 and the high rebound elasticity of the material constituting the third layer 33 contribute to preventing the body from sinking too much.

[0054] When a user with a body weight of about 49 kg places their body on the cushion body 1, a load of about 230 N is applied near the waist. In FIG. 3, the amount of sinking corresponding to a stress of about 230 N is about 40 mm. As the amount of sinking is increased from 40 mm to 45 mm, the increase amount of stress per unit amount of sinking decreases. As a result, the graph in the range where the amount of sinking is from 40 mm to 45 mm exhibits a bulging shape.

[0055] In areas where the stress is high, the fact that the graph exhibits such a bulging shape indicates that the portion compressed by the load is hard and has appropriate rebound elasticity. That is, when a user applies a load of about 230 N, since the compressed portion is hard, the user can be reliably supported, and since the compressed portion has appropriate rebound elasticity, it indicates that the body can be prevented from sinking too much.

[0056] When the cushion body 1 is depressed by 40 mm to 45 mm, the user's body mainly applies a load to and compresses the first layer 31, the second layer 32, the third layer 33, and the lower layer member 14. Therefore, when an upper elementary school child is the user, the high hardness of the material constituting the lower layer member 14 contributes to reliably supporting the user. When an upper elementary school child is the user, the high resilience of the material constituting the first layer 31 and the high resilience of the material constituting the third layer 33 contribute to suppressing the body from sinking too much.

[0057] In addition, the lower layer member 14 has an uneven structure that contacts the third layer 33. Therefore, when the user's body depresses the upper layer member 13, the lower layer member 14 partially applies a resistance force to the user's body by the convex portion 15 of the uneven structure. Thereby, it is possible to suppress the user from feeling a sudden change in hardness received from the lower layer member 14 when the upper layer member 13 is depressed. Further, the convex portion 15 includes an upper surface 15a that is in surface contact with the lower surface 33b of the third layer 33. Since the upper surface 15a of the convex portion 15 is in surface contact with the lower surface 33b of the third layer 33, the upper layer member 13 can be stably placed on the lower layer member 14. Thereby, since the lower layer member 14 can be bonded to the third layer 33 in a stable state, the lower layer member 14 can be reliably bonded to the third layer 33. The ability to suppress the body from sinking too much when the user places the body on the cushion body 1 and the ability to suppress the stuffiness generated in the cushion body 1 are common effects obtained for the reasons described above even when a child with a heavier weight is the user. Therefore, even when a child with a heavier weight is the user, a comfortable sleeping comfort can be provided to the user. As a result, even when the amount of change in the user's weight is large, a comfortable sleeping comfort can be continuously provided to the user.

[0058] The lower surface 31b of the first layer 31 is adhesively bonded to the upper surface 32a of the second layer 32 by an elastic adhesive 34. The lower surface 32b of the second layer 32 is adhesively bonded to the upper surface 33a of the third layer 33 by an elastic adhesive 35. Thus, it is possible to adjust the hardness of the upper layer member 13 according to the amounts of the elastic adhesives 34 and 35. That is, the hardness of the upper layer member 13 can be adjusted by adjusting the amounts of the elastic adhesive 34 between the first layer 31 and the second layer 32 and the elastic adhesive 35 between the second layer 32 and the third layer 33.

[0059] The material constituting the first layer 31 is the same as the material constituting the third layer 33. Thus, by preparing one material, the first layer 31 and the third layer 33 can be produced. Therefore, since the types of materials to be prepared can be reduced, the production of the cushion body 1 can be easily performed.

[0060] The material constituting the second layer 32 is the same as the material constituting the lower layer member 14. Thus, by preparing one material, the second layer 32 and the lower layer member 14 can be produced. Therefore, since the types of materials to be prepared can be reduced, the production of the cushion body 1 can be easily performed.

[0061] Next, an example of a method for manufacturing the cushion body according to the present embodiment will be described with reference to FIG. 4. FIG. 4 is a flowchart showing an example of a method for manufacturing the cushion body. The method for manufacturing the cushion body may be used for the cushion body 1 described above or for a cushion body other than the cushion body 1. First, as shown in FIG. 5, a first layer M31 made of the same material as the material constituting the first layer 31, a second layer M32 made of the same material as the material constituting the second layer 32, and a third layer M33 made of the same material as the material constituting the third layer 33 are prepared. FIG. 5 is a side view of a block body B described later. The first layer M31, the second layer M32, and the third layer M33 are in a plate shape.

[0062] The hardness of the material constituting the first layer M31 is lower than the hardness of the material constituting the second layer M32. The hardness of the material constituting the third layer M33 is lower than the hardness of the material constituting the second layer M32. The resilience of the material constituting the first layer M31 is higher than the resilience of the material constituting the second layer M32. The resilience of the material constituting the third layer M33 is higher than the resilience of the material constituting the second layer M32.

[0063] The 40% hardness of the material constituting the first layer M31 is, for example, 120 N or more and 180 N or less. The resilience of the material constituting the first layer M31 is, for example, 50% or more and 70% or less. The 40% hardness of the material constituting the second layer M32 is, for example, 190 N or more and 250 N or less. The resilience of the material constituting the second layer M32 is, for example, 35% or more and 50% or less. The 40% hardness of the material constituting the third layer M33 is, for example, 120 N or more and 180 N or less. The resilience of the material constituting the third layer M33 is, for example, 50% or more and 70% or less. The first layer M31 is constituted by, for example, HKI. The second layer M32 is constituted by, for example, HKE. The third layer M33 is constituted by, for example, HKI.

[0064] Each of the first layer M31, the second layer M32, and the third layer M33 extends in both the first direction D1 and the second direction D2. Each of the first layer M31, the second layer M32, and the third layer M33 has a thickness in the third direction D3. For example, the thickness of the first layer M31 is equal to the thickness of the third layer M33. For example, the thickness of the second layer M32 is smaller than the thickness of the first layer M31 and the thickness of the third layer M33.

[0065] A block body B is produced by laminating the second layer M32 on the third layer M33 and laminating the first layer M31 on the second layer M32 (a step of producing a block body, step S1). The block body B includes the first layer M31, the second layer M32, and the third layer M33. The first layer M31 has a lower surface M31b. The second layer M32 has an upper surface M32a and a lower surface M32b facing the side opposite to the upper surface M32a. The third layer M33 has an upper surface M33a and a lower surface M33b facing the side opposite to the upper surface M33a.

[0066] The second layer M32 is laminated on the third layer M33 such that the lower surface M32b faces the upper surface M33a. The second layer M32 is adhered to the third layer M33. More specifically, the second layer M32 is adhered to the third layer M33 by adhering the lower surface M32b to the upper surface M33a with an elastic adhesive 35. The first layer M31 is laminated on the second layer M32 such that the lower surface M31b faces the upper surface M32a. The first layer M31 is adhered to the second layer M32. More specifically, the first layer M31 is adhered to the second layer M32 by adhering the lower surface M31b to the upper surface M32a with an elastic adhesive 34.

[0067] The hardness of the material constituting the elastic adhesive 34 when cured is higher than the hardness of the material constituting the first layer M31. The hardness of the material constituting the elastic adhesive 34 when cured is higher than the hardness of the material constituting the second layer M32. The hardness of the material constituting the elastic adhesive 35 when cured is higher than the hardness of the material constituting the second layer M32. The hardness of the material constituting the elastic adhesive 35 when cured is higher than the hardness of the material constituting the third layer M33. By adjusting the respective amounts of the elastic adhesives 34 and 35, the hardness of the upper layer member 13 produced in the process described later can be adjusted. By adjusting the respective amounts of the elastic adhesives 34 and 35, the length of the upper layer member 13 in the third direction D3 produced in the process described later can be adjusted.

[0068] For example, the weight of the elastic adhesive 34 to be applied and the weight of the elastic adhesive 35 to be applied each adjust the hardness of the upper layer member 13. When the weight of the elastic adhesive 34 to be applied or the weight of the elastic adhesive 35 to be applied increases, the hardness of the upper layer member 13 is increased. When the weight of the elastic adhesive 34 to be applied or the weight of the elastic adhesive 35 to be applied decreases, the hardness of the upper layer member 13 is decreased. The hardness of the upper layer member 13 may be adjusted by the thickness of the elastic adhesive 34 when cured and the thickness of the elastic adhesive 35 when cured, respectively. When the thickness of the elastic adhesive 34 when cured or the thickness of the elastic adhesive 35 when cured increases, the hardness of the upper layer member 13 is increased. When the thickness of the elastic adhesive 34 when cured or the thickness of the elastic adhesive 35 when cured decreases, the hardness of the upper layer member 13 is decreased. For example, the thickness of the elastic adhesive 34 when cured is adjusted by the weight of the elastic adhesive 34 to be applied. For example, the thickness of the elastic adhesive 35 when cured is adjusted by the weight of the elastic adhesive 35 to be applied.

[0069] With reference to FIG. 6, a method of applying the elastic adhesives 34 and 35 to the members constituting the block body B will be described. FIG. 6 is a schematic diagram of an apparatus D for applying the elastic adhesive 34 (or the elastic adhesive 35) to the members constituting the block body B. The apparatus D applies the elastic adhesive 34 to the base material M. The base material M is, for example, the first layer M31, the second layer M32, or the third layer M33. The apparatus D has a roll R1 that advances the base material M in the fourth direction D4, a roll R2 that is aligned with the roll R1 along a fifth direction D5 that intersects the fourth direction D4, and a roll R3 that is adjacent to the roll R1 along the fourth direction D4. The fifth direction D5 is, for example, the vertical direction. Rubber is attached to the outer peripheral surfaces of the roll R1 and the roll R2.

[0070] A gap through which the base material M can pass is provided between the roll R1 and the roll R2. The roll R2 rotates in a direction opposite to that of the roll R1. In FIG. 6, the roll R1 rotates counterclockwise and the roll R2 rotates clockwise. The base material M is sandwiched between the roll R1 and the roll R2 and advances in the fourth direction D4 as the roll R1 and the roll R2 rotate.

[0071] The roll R3 is separated from the base material M in the fifth direction D5. A gap s is provided between the roll R3 and the roll R1. The minimum length of the gap s is, for example, 0.01 mm or more and 0.10 mm or less. The minimum length of the gap s is, for example, 0.05 mm. The roll R3 rotates in a direction opposite to that of the roll R1. An elastic adhesive 34 is stored above the gap s (on the side opposite to the side where the base material M is located). As the roll R3 rotates, the stored elastic adhesive 34 passes through the gap s. A certain amount of the stored elastic adhesive 34 passes through the gap s. The elastic adhesive 34 that has passed through the gap s adheres to the outer peripheral surface of the roll R1. The elastic adhesive 34 adhering to the outer peripheral surface of the roll R1 approaches the base material M as the roll R1 rotates. The elastic adhesive 34 adhering to the outer peripheral surface of the roll R1 is applied to the base material M when it is sandwiched between the roll R1 and the base material M. In this way, the elastic adhesive 34 is applied to one side surface of the base material M in the fifth direction D5. In the method of applying the elastic adhesive 35 to the base material M, a device similar to the device D is also used.

[0072] Subsequently, as shown in FIG. 5, the block body B is cut (the step of cutting the block body B, step S2). The block body B is cut along a meandering virtual cutting line L1. The cutting line L1 meanders by alternately switching the direction from the first layer M31 to the third layer M33 and the direction from the third layer M33 to the first layer M31 along the third direction D3. The cutting line L1 is constituted by a smooth curve when viewed from the side surface of the block body B. The cutting line L1 has a plurality of tops Lp1, Lp2 which are the portions where the direction from the first layer M31 to the third layer M33 and the direction from the third layer M33 to the first layer M31 are switched. The top Lp1 is the portion where the direction is switched from the direction from the third layer M33 to the first layer M31 to the direction from the first layer M31 to the third layer M33. The top Lp2 is the portion where the direction is switched from the direction from the first layer M31 to the third layer M33 to the direction from the third layer M33 to the first layer M31.

[0073] Each of the plurality of tops Lp1 is located inside the first layer M31. Each of the plurality of tops Lp2 is located inside the third layer M33. That is, the cutting line L1 reciprocates from the first layer M31 to the third layer M33. A part of the plurality of tops Lp1 may be located in the second layer M32. A part of the plurality of tops Lp2 may be located in the second layer M32.

[0074] In step S2, by cutting the block body B along the cutting line L1, the upper layer member 13 is produced. The cutting of the block body B along the cutting line L1 is performed, for example, by a profiling machine. In this case, the block body B is passed between the uneven portions formed on the surfaces of a pair of rollers of the profiling machine, and the block body B is cut while being pressed in the direction in which the pair of rollers are arranged by the uneven portions, whereby the cutting of the block body B along the cutting line L1 is realized.

[0075] FIG. 7 is a side view of the upper layer member 13. As shown in FIGS. 5 and 7, the portion of the first layer M31 located between the cutting line L1 and the elastic adhesive 34 constitutes the first layer 31. The portion defined by the cutting line L1 and the elastic adhesives 34 and 35 constitutes the second layer 32. The third layer M33 from which the portion located between the cutting line L1 and the elastic adhesive 35 has been removed constitutes the third layer 33. By cutting the block body B along the cutting line L1 in this way, the first layer 31, the second layer 32, and the third layer 33 are formed, and the convex portion 11 and the concave portion 12 are formed. The upper layer member 13 has an uneven structure constituted by the convex portion 11 and the concave portion 12.

[0076] When the material constituting the first layer M31 is the same as the material constituting the third layer M33, two upper layer members 13 can be produced by cutting the block body B along the cutting line L1. Thereby, when producing the upper layer member 13, the amount of material to be disposed of can be reduced.

[0077] Subsequently, as shown in FIG. 8, a lower layer member M14 made of the same material as the material constituting the lower layer member 14 is prepared. FIG. 8 is a side view of the lower layer member M14. The lower layer member M14 has a plate shape. The lower layer member M14 extends in both the first direction D1 and the second direction D2. The lower layer member M14 has a thickness in the third direction D3. The length of the prepared lower layer member M14 in the third direction D3 is longer than the length of the produced lower layer member 14 in the third direction D3.

[0078] The hardness of the material forming the first layer M31 is lower than the hardness of the material forming the lower member M14. The hardness of the material forming the third layer M33 is lower than the hardness of the material forming the lower member M14. The resilience of the material forming the first layer M31 is higher than the resilience of the material forming the lower member M14. The resilience of the material forming the third layer M33 is higher than the resilience of the material forming the lower member M14. The 40% hardness of the material forming the lower member M14 is, for example, 190 N or more and 250 N or less. The resilience of the material forming the lower member M14 is, for example, 35% or more and 50% or less. The lower member M14 is formed by, for example, HKE.

[0079] The lower member M14 has an upper surface M14a and a lower surface M14b facing the side opposite to the upper surface M14a. The lower member M14 is cut along a virtual cutting line L2 that meanders through the lower member M14 (step S3 of cutting the lower member). The cutting line L2 meanders by alternately switching between the direction from the upper surface 14a to the lower surface 14b and the direction from the lower surface 14b to the upper surface 14a. The cutting line L2 is composed of a smooth curve when viewed from the side of the lower member M14.

[0080] The cutting of the lower member M14 along the cutting line L2 is performed, for example, by a profiling machine. In this case, the lower member M14 is passed between the uneven portions formed on the surfaces of a pair of rollers of the profiling machine, and the lower member M14 is cut while being pressed in the direction in which the pair of rollers are arranged by the uneven portions, thereby realizing the cutting of the lower member M14 along the cutting line L2.

[0081] As shown in FIG. 9, by cutting the lower layer member M14, the lower layer member M14A is produced. FIG. 9 is a side view of the lower layer member M14A. The lower layer member M14A has a concavo-convex structure on the upper surface opposite to the lower surface M14b. The lower layer member M14A has, for example, a plurality of convex portions M15 protruding in the third direction D3 and a plurality of concave portions M16 recessed in the third direction D3. For example, the plurality of convex portions M15 are arranged along each of the first direction D1 and the second direction D2, and the plurality of concave portions M16 are arranged along each of the first direction D1 and the second direction D2. That is, the plurality of convex portions M15 and the plurality of concave portions M16 are arranged in a lattice pattern on the upper surface of the lower layer member M14A. The plurality of convex portions M15 and the plurality of concave portions M16 exhibit a corrugated shape on the upper surface of the lower layer member M14A.

[0082] Subsequently, an upper surface is formed on the convex portion M15 of the lower layer member M14A (step of forming an upper surface on the convex portion of the lower layer member, step S4). The "upper surface" is a surface formed by cutting the top of the convex portion M15, and is, for example, a surface having a smaller curvature than the curved surface of the convex portion M15 before the upper surface is formed. As an example, the "upper surface" is a flat surface. By cutting the convex portion M15 of the lower layer member M14A, an upper surface is formed on the convex portion M15. The lower layer member M14A is cut along a virtual cutting line L3 extending along the lower surface 33b of the third layer 33. The cutting line L3 is orthogonal to the third direction D3. The cutting line L3 is, for example, a straight line. The cutting line L3 passes through substantially the center of the convex portion M15 in the third direction D3.

[0083] FIG. 10 is a side view of the lower layer member 14. By cutting the lower layer member M14A along the cutting line L3, the upper portion of the convex portion M15 is removed. As a result, a plurality of convex portions 15 having an upper surface 15a and a plurality of concave portions 16 are formed. By steps S3 and S4, a concavo-convex structure is formed in the lower layer member M14, and the lower layer member 14 having the concavo-convex structure is produced. The concavo-convex structure may be formed in the lower layer member M14 by a method other than the methods shown in steps S3 and S4. For example, a lower layer member having a thickness equal to the thickness of the lower layer member 14 may be prepared, and a plurality of concave portions may be formed on the upper surface of the lower layer member.

[0084] Subsequently, as shown in FIGS. 2 and 10, the concavo-convex structure of the lower layer member 14 is attached to the third layer 33 (the step of attaching the concavo-convex structure of the lower layer member to the third layer, step S5). By attaching the upper surface 15a of the convex portion 15 to the lower surface 33b of the third layer 33, the concavo-convex structure of the lower layer member 14 is attached to the third layer 33. The lower surface 33b is the surface on the opposite side of the upper surface 33a facing the second layer 32. By attaching the concavo-convex structure of the lower layer member 14 to the third layer 33, the upper layer member 13 is attached to the lower layer member 14.

[0085] More specifically, the upper surface 15a is attached to the lower surface 33b by the elastic adhesive 17. The method of applying the elastic adhesive 17 to the upper surface 15a or the lower surface 33b is the same as the method of applying the elastic adhesive 34 to the base material M. By adjusting the amount of the elastic adhesive 17 applied, the hardness of the produced cushion body can be adjusted.

[0086] For example, the weight of the elastic adhesive 17 applied adjusts the hardness of the cushion body 1. When the weight of the elastic adhesive 17 applied increases, the hardness of the cushion body 1 is increased. When the weight of the elastic adhesive 17 applied decreases, the hardness of the cushion body 1 is decreased. The hardness of the cushion body 1 may be adjusted by the thickness of the elastic adhesive 17 when it is cured. When the thickness of the elastic adhesive 17 when it is cured increases, the hardness of the cushion body 1 is increased. When the thickness of the elastic adhesive 17 when it is cured decreases, the hardness of the cushion body 1 is decreased. For example, the thickness of the elastic adhesive 17 when it is cured is adjusted by the weight of the elastic adhesive 17 applied.

[0087] Next, the effects obtained from the manufacturing method of the cushion body according to the present embodiment will be described. In this manufacturing method of the cushion body, after producing the block body B including the first layer M31, the second layer M32, and the third layer M33, the upper layer member 13 having the concavo-convex structure is produced from the block body B. Further, the lower layer member M14 is prepared independently of the step of producing the upper layer member 13, and the concavo-convex structure is formed on the lower layer member M14. Therefore, since the concavo-convex structure can be formed on the single lower layer member M14, the concavo-convex structure can be easily formed on the lower layer member M14. Further, in order to form the concavo-convex structure on the upper layer member 13, the block body B is cut along the cutting line L1 that meanders so as to reciprocate from the first layer M31 to the third layer M33. Therefore, a plurality of convex portions 11 and a plurality of concave portions 12 included in the concavo-convex structure of the upper layer member 13 are formed. Thereby, when the user places the body on the cushion body, the feel obtained by the user from the convex portion 11 can be improved. In the present embodiment, the plurality of convex portions 11 and the plurality of concave portions 12 have a waveform shape. Therefore, the feel obtained by the user from the convex portion 11 can be further improved.

[0088] The step of producing the block body B includes a step of bonding the upper surface M32a to the lower surface M31b with the elastic adhesive 34, and a step of bonding the upper surface M33a to the lower surface M32b with the elastic adhesive 35. In each of the step of bonding the upper surface M32a and the step of bonding the upper surface M33a, the hardness of the upper layer member 13 is adjusted by adjusting the amount of each of the elastic adhesives 34 and 35. In this case, the hardness of the upper layer member 13 can be adjusted by the amount of the elastic adhesive 34 applied between the first layer M31 and the second layer M32 and the amount of the elastic adhesive 35 applied between the second layer M32 and the third layer M33.

[0089] The step of forming the concavo-convex structure on the lower member M14 includes the step of forming the upper surface 15a of the convex portion 15 by cutting each of the plurality of convex portions M15 constituting the concavo-convex structure of the lower member M14A along the lower surface 33b of the third layer 33. In the step of attaching the lower member 14 to the third layer 33, the lower surface 33b of the third layer 33 opposite to the second layer 32 is bonded to the upper surface 15a of the convex portion 15. In this case, since the upper surface 15a of the convex portion 15 is formed by cutting each of the plurality of convex portions M15 along the lower surface 33b of the third layer 33, the lower surface 33b of the third layer 33 can be brought into surface contact with the upper surface 15a of the convex portion 15. By bringing the upper surface 15a of the convex portion 15 into surface contact with the lower surface 33b of the third layer 33, the upper member 13 can be stably placed on the lower member 14. Thereby, since the lower member 14 can be bonded to the third layer 33 in a stable state, the lower member 14 can be surely bonded to the third layer 33.

[0090] Next, with reference to FIGS. 11 to 13, a cushion body 1A according to another embodiment will be described. FIG. 11 is a plan view of the cushion body 1A. FIG. 12 is a plan view of the lower member 14A of the cushion body 1A. FIG. 13 is a cross-sectional view taken along line XIII-XIII of FIG. 11. The cushion body 1A is used, for example, as a bedding such as a pillow. In the present embodiment, an example in which the cushion body 1A is a pillow will be described. The cushion body 1A is, for example, housed in a stain-proof cover and used. The cushion body 1A is composed of a flexible material.

[0091] The cushion body 1A has, for example, an upper surface 1Aa on which a user's head is placed and a lower surface 1Ab facing the side opposite to the upper surface 1Aa. As an example, unevenness including convex portions 11A and concave portions 12A is formed on the upper surface 1Aa, and the lower surface 1Ab is flat. The convex portions 11A and the concave portions 12A will be described in detail later.

[0092] The cushion body 1A has a rectangular shape in plan view. The cushion body 1A has a long side 1Ac extending in the first direction D1 and a short side 1Ad extending in the second direction D2 in plan view. In the present embodiment, the first direction D1 indicates the longitudinal direction of the cushion body 1A, and the second direction D2 indicates the lateral direction of the cushion body 1A. The length of the long side 1Ac is, for example, 550 mm or more and 850 mm or less. The length of the short side 1Ad is 350 mm or more and 550 mm or less.

[0093] The central portion of the long side 1Ac is curved inward of the cushion body 1A in plan view. Therefore, the length of the cushion body 1A in the second direction D2 at the central portion in the first direction D1 is shorter than the length of the cushion body 1A in the second direction D2 at the end portion in the first direction D1. The cushion body 1A has a thickness in the third direction D3. The length of the cushion body 1A in the third direction D3 at the central portion in the first direction D1 is shorter than the length of the cushion body 1A in the third direction D3 at the end portion in the first direction D1.

[0094] The upper surface 1Aa includes, for the sake of convenience, a portion extending in both the first direction D1 and the second direction D2, and a portion extending in the third direction D3 from the outer edge of the portion in plan view. Thus, the upper surface 1Aa may not intersect the third direction D3. The upper surface 1Aa is connected to the lower surface 1Ab via a portion extending in both the first direction D1 and the third direction D3 and a portion extending in both the second direction D2 and the third direction D3, respectively.

[0095] Hereinafter, the “direction intersecting the upper surface 1Aa” refers to the third direction D3 in the portion of the upper surface 1Aa extending in both the first direction D1 and the second direction D2, refers to the second direction D2 in the portion of the upper surface 1Aa extending in both the first direction D1 and the third direction D3, and refers to the first direction D1 in the portion of the upper surface 1Aa extending in both the second direction D2 and the third direction D3. Also, the “direction along the upper surface 1Aa” refers to each of the first direction D1 and the second direction D2 in the portion of the upper surface 1Aa extending in both the first direction D1 and the second direction D2, refers to each of the first direction D1 and the third direction D3 in the portion of the upper surface 1Aa extending in both the first direction D1 and the third direction D3, and refers to each of the second direction D2 and the third direction D3 in the portion of the upper surface 1Aa extending in both the second direction D2 and the third direction D3.

[0096] The cushion body 1A has, for example, a plurality of convex portions 11A protruding so as to intersect the upper surface 1Aa and a plurality of concave portions 12A recessed so as to intersect the upper surface 1Aa. For example, in the portion of the upper surface 1Aa extending in both the first direction D1 and the second direction D2, the convex portion 11A protrudes in the third direction D3, and the concave portion 12A is recessed in the third direction D3.

[0097] For example, the plurality of convex portions 11A are arranged in a lattice pattern in the direction along the upper surface 1Aa, and the plurality of concave portions 12A are arranged in a lattice pattern in the direction along the upper surface 1Aa. That is, the plurality of convex portions 11A are arranged side by side along each of the first direction D1 and the second direction D2, and the plurality of concave portions 12A are arranged side by side along each of the first direction D1 and the second direction D2. Also, in each of the portion of the upper surface 1Aa extending in both the first direction D1 and the third direction D3 and the portion of the upper surface 1Aa extending in both the second direction D2 and the third direction D3, each of the plurality of convex portions 11A and the plurality of concave portions 12A is arranged in a lattice pattern in the direction along the upper surface 1Aa.

[0098] As shown in FIG. 13, the plurality of convex portions 11A have upper surfaces 11Aa extending along the upper surface 1Aa of the cushion body 1A. The cushion body 1A includes an upper layer member 13A including the upper surface 1Aa and a lower layer member 14A including the lower surface 1Ab. The upper layer member 13A is laminated so as to cover the lower layer member 14A. The upper layer member 13A has a plurality of layers laminated along a direction intersecting the upper surface 1Aa. The upper layer member 13A has a third layer 33A, a second layer 32A laminated so as to cover the third layer 33A, and a first layer 31A laminated so as to cover the second layer 32A. The upper layer member 13A has an uneven structure constituted by a plurality of convex portions 11A and a plurality of concave portions 12A. The upper surface 11Aa of the convex portion 11A is included in the first layer 31A. The bottom of the concave portion 12A is included in the third layer 33A. Thus, the uneven structure extends from the first layer 31A to the third layer 33A.

[0099] The first layer 31A constitutes a part of the convex portion 11A including the upper surface 11Aa. The first layer 31A has a substantially trapezoidal shape in a side view of the cushion body 1A. The outer contour of the first layer 31A is rounded. The first layer 31A included in each of the plurality of convex portions 11A is not connected to the first layer 31A different from the first layer 31A. That is, the plurality of first layers 31A constituting the upper side portions of the convex portions 11A are independent of each other. The first layer 31A has a lower surface 31Ab facing the side opposite to the upper surface 11Aa. The lower surface 31Ab is a curved surface.

[0100] The hardness of the material constituting the first layer 31A is lower than the hardness of the material constituting the second layer 32A. The hardness of the material constituting the first layer 31A is lower than the hardness of the material constituting the lower layer member 14A. The 40% hardness of the material constituting the first layer 31A is, for example, 120 N or more and 180 N or less.

[0101] The resilience of the material constituting the first layer 31A is higher than the resilience of the material constituting the second layer 32A. The resilience of the material constituting the first layer 31A is higher than the resilience of the material constituting the lower layer member 14A. The resilience of the material constituting the first layer 31A is, for example, 50% or more and 70% or less. The first layer 31A is constituted by, for example, HKI.

[0102] The second layer 32A constitutes a part of the convex portion 11A (the central portion in the height direction of the convex portion 11A). The second layer 32A has a trapezoidal shape when viewed from the side of the cushion body 1A. The second layer 32A has an upper surface 32Aa facing the lower surface 31Ab and a lower surface 32Ab facing the side opposite to the upper surface 32Aa. The upper surface 32Aa is a curved surface. The lower surface 32Ab is a curved surface. The side surface connecting the upper surface 32Aa to the lower surface 32Ab is a curved surface.

[0103] The 40% hardness of the material constituting the second layer 32A is, for example, 190 N or more and 250 N or less. The resilience of the material constituting the second layer 32A is, for example, 35% or more and 50% or less. The second layer 32A is constituted by, for example, HKE.

[0104] The third layer 33A constitutes a part of the convex portion 11A (the lowermost part) and includes the bottom of the concave portion 12A. The third layer 33A has an upper surface 33Aa facing the lower surface 32Ab and a lower surface 33Ab facing the side opposite to the upper surface 33Aa. The upper surface 33Aa is a curved surface. The lower surface 33Ab is a curved surface. The lower surface 33Ab constitutes the lower surface of the upper layer member 13A. The hardness of the material constituting the third layer 33A is lower than the hardness of the material constituting the second layer 32A. The hardness of the material constituting the third layer 33A is lower than the hardness of the material constituting the lower layer member 14A. The resilience of the material constituting the third layer 33A is higher than the resilience of the material constituting the second layer 32A. The resilience of the material constituting the third layer 33A is higher than the resilience of the material constituting the lower layer member 14A. The material constituting the third layer 33A is the same as the material constituting the first layer 31A. The material constituting the third layer 33A may be different from the material constituting the first layer 31A.

[0105] The 40% hardness of the material constituting the third layer 33A is, for example, 120 N or more and 180 N or less. The resilience of the material constituting the third layer 33A is, for example, 50% or more and 70% or less. The third layer 33A is constituted by, for example, HKI.

[0106] The upper member 13A has an elastic adhesive 34A for bonding the first layer 31A to the second layer 32A and an elastic adhesive 35A for bonding the second layer 32A to the third layer 33A. The elastic adhesive 34A is interposed between the lower surface 31Ab of the first layer 31A and the upper surface 32Aa of the second layer 32A. The hardness of the elastic adhesive 34A when cured is higher than the hardness of the material constituting the first layer 31A. The hardness of the elastic adhesive 34A when cured is higher than the hardness of the material constituting the second layer 32A. The elastic adhesive 34A is, for example, a hot melt adhesive.

[0107] The elastic adhesive 35A bonds the lower surface 32Ab of the second layer 32A to the upper surface 33Aa of the third layer 33A. The hardness of the elastic adhesive 35A when cured is higher than the hardness of the material constituting the second layer 32A. The hardness of the elastic adhesive 35A when cured is higher than the hardness of the material constituting the third layer 33A. The elastic adhesive 35A is, for example, a hot melt adhesive. The material constituting the elastic adhesive 35A may be the same as the material constituting the elastic adhesive 34A. The material constituting the elastic adhesive 35A may be different from the material constituting the elastic adhesive 34A.

[0108] The hardness of the upper member 13A is contributed by each of the first layer 31A, the second layer 32A, the third layer 33A, the elastic adhesive 34A, and the elastic adhesive 35A. The hardness of the upper member 13A is contributed by the hardness of the material constituting the first layer 31A and the weight (or thickness) of the first layer 31A. The hardness of the upper member 13A is contributed by the hardness of the material constituting the second layer 32A and the weight (or thickness) of the second layer 32A. The hardness of the upper member 13A is contributed by the hardness of the material constituting the third layer 33A and the weight (or thickness) of the third layer 33A. The hardness of the upper member 13A is contributed by the hardness of the elastic adhesive 34A when cured and the weight (or thickness) of the elastic adhesive 34A that the upper member 13A has. The hardness of the upper member 13A is contributed by the hardness of the elastic adhesive 35A when cured and the weight (or thickness) of the elastic adhesive 35A that the upper member 13A has.

[0109] The hardness of the upper member 13A is adjusted, for example, by the weight of the elastic adhesive 34A and the weight of the elastic adhesive 35A respectively. When the weight of the elastic adhesive 34A or the weight of the elastic adhesive 35A increases, the hardness of the upper member 13A is increased. When the weight of the elastic adhesive 34A or the weight of the elastic adhesive 35A decreases, the hardness of the upper member 13A is decreased. The hardness of the upper member 13A may be adjusted by the thickness of the elastic adhesive 34A when cured and the thickness of the elastic adhesive 35A when cured respectively. When the thickness of the elastic adhesive 34A when cured or the thickness of the elastic adhesive 35A when cured increases, the hardness of the upper member 13A is increased. When the thickness of the elastic adhesive 34A when cured or the thickness of the elastic adhesive 35A when cured decreases, the hardness of the upper member 13A is decreased.

[0110] The lower member 14A has a single layer. The lower member 14A is formed by urethane molding. The material constituting the lower member 14A is different from the material constituting the second layer 32A. The lower member 14 is constituted by, for example, foamed urethane. The 40% hardness of the material constituting the lower member 14A is, for example, 30 N or more and 60 N or less. The resilience of the material constituting the lower member 14A is, for example, 10% or more and 20% or less. The resilience of the material constituting the lower member 14A is, for example, 15%.

[0111] The lower member 14A has an upper surface 14Aa facing the lower surface 33Ab of the third layer 33A. The lower surface of the lower member 14A facing the opposite side forms the lower surface 1Ab. The lower member 14A has an uneven structure provided on the upper surface 14Aa. More specifically, the lower member 14A has, for example, a plurality of convex portions 15A protruding in a direction intersecting the upper surface 1Aa and a plurality of concave portions 16A recessed in a direction intersecting the upper surface 1Aa. The uneven structure of the lower member 14A is constituted by the plurality of convex portions 15A and the plurality of concave portions 16A. For example, the plurality of convex portions 15A are arranged in a staggered pattern. For example, the plurality of concave portions 16A are arranged in a staggered pattern.

[0112] The convex portion 15A has an upper surface 15Aa that faces the lower surface 33Ab. The upper surface 15Aa is a curved surface. The upper surface 15Aa follows the lower surface 33Ab. The upper surface 15Aa is in contact with the lower surface 33Ab. The upper surface 15Aa is in surface contact with the lower surface 33Ab. Due to the upper surface 15Aa being in surface contact with the lower surface 33Ab, the uneven structure of the lower layer member 14A is in contact with the third layer 33A.

[0113] The concave portion 16A is part of a waveform shape. The convex portions 15A are arranged along the direction in which the convex portion 11A and the upper surface 1Aa intersect. The concave portions 16A are arranged along the direction in which the concave portion 12A and the upper surface 1Aa intersect. The convex portions 15A do not necessarily have to be arranged along the direction in which the convex portion 11A and the upper surface 1Aa intersect. The concave portions 16A do not necessarily have to be arranged along the direction in which the concave portion 12A and the upper surface 1Aa intersect.

[0114] In the cushion body 1A, the upper layer member 13A is bonded to the lower layer member 14A by a water-soluble adhesive. The water-soluble adhesive is composed of a material that hardens when it absorbs moisture in the air. The water-soluble adhesive is applied to the lower layer member 14A using a spray gun. Examples of the water-soluble adhesive include, for example, water-based rubber adhesives.

[0115] Next, the effects obtained from the cushion body 1A according to the present embodiment will be described. In this cushion body 1A, the hardness of the material constituting the first layer 31A and the hardness of the material constituting the third layer 33A are lower than the hardness of the material constituting the lower layer member 14A. Therefore, for example, in the case of a user with a light head weight, the first layer 31A and the third layer 33A have higher flexibility, so that the cushion body 1A can be appropriately deformed to fit the user's head. Further, the hardness of the material constituting the second layer 32A is higher than the hardness of the material constituting the first layer 31A and the hardness of the material constituting the third layer 33A. Therefore, the harder second layer 32A can reliably support the head with a light weight. Further, the resilience of the material constituting the first layer 31A and the resilience of the material constituting the third layer 33A are each higher than the resilience of the material constituting the second layer 32A and the resilience of the material constituting the lower layer member 14A. Therefore, when the user places the head on the cushion body 1A, it is possible to suppress the head from sinking too much. Further, when the user is a child, there is a concern that the amount of sweating will be more than that of an adult. In this cushion body 1A, the lower layer member 14A has an uneven structure that contacts the third layer 33A. Therefore, since the air permeability inside the cushion body 1A is enhanced, it is possible to suppress the stuffiness generated in the cushion body 1A. Therefore, when the user has a light head weight, it is possible to provide the user with a comfortable sleeping comfort.

[0116] In this cushion body 1A, the hardness of the material constituting the lower layer member 14A is higher than the hardness of the material constituting the first layer 31A and the hardness of the material constituting the third layer 33A. Therefore, for example, in the case of a user with a heavy head weight, the lower layer member 14A can reliably support the user's head. Further, the lower layer member 14A has an uneven structure that contacts the third layer 33A. Therefore, when the user's head sinks the upper layer member 13A, the lower layer member 14A partially applies a resistance force to the user's head. Thereby, it is possible to suppress the user from feeling a sudden change in hardness between the hardness of the upper layer member 13A and the hardness of the lower layer member 14A. Further, the convex portion 15A includes an upper surface 15Aa that is in surface contact with the lower surface 33Ab of the third layer 33A. Since the upper surface 15Aa of the convex portion 15A is in surface contact with the lower surface 33Ab of the third layer 33A, the upper layer member 13A can be stably placed on the lower layer member 14A. Thereby, since the lower layer member 14A can be bonded to the third layer 33A in a stable state, the lower layer member 14A can be reliably bonded to the third layer 33A. The ability to suppress the head from sinking too much when the user places their head on the cushion body 1A and the ability to suppress the stuffiness that occurs in the cushion body 1A are common effects obtained for users with heavy head weights for the reasons described above. Therefore, even in the case of a user with a heavy head weight, a comfortable sleeping comfort can be provided to the user. As a result, even when the amount of fluctuation in the weight of the user's head is large, a comfortable sleeping comfort can be continuously provided to the user.

[0117] The lower surface 31Ab of the first layer 31A is bonded to the upper surface 32Aa of the second layer 32A by an elastic adhesive 34A. The lower surface 32Ab of the second layer 32A is bonded to the upper surface 33Aa of the third layer 33A by an elastic adhesive 35A. Thereby, it is possible to adjust the hardness of the upper layer member 13A according to the amount of the elastic adhesives 34A and 35A. That is, by adjusting the amount of the elastic adhesive 34A between the first layer 31A and the second layer 32A and the amount of the elastic adhesive 35A between the second layer 32A and the third layer 33A, the hardness of the upper layer member 13A can be adjusted.

[0118] The material constituting the first layer 31A is the same as the material constituting the third layer 33A. By doing so, by preparing one material, the first layer 31A and the third layer 33A can be manufactured. Therefore, the types of materials to be prepared can be reduced, and the manufacture of the cushion body 1A can be easily performed.

[0119] As described above, various embodiments of the cushion body and the method for manufacturing the cushion body according to the present disclosure have been described. However, the cushion body and the method for manufacturing the cushion body according to the present disclosure are not limited to the above-described embodiments, and may be further modified within the scope of the gist described in the claims. The shape, size, material, number, and arrangement mode of each part of the cushion body according to the present disclosure can be appropriately changed within the scope of the above gist.

[0120] The cushion body 1 had elastic adhesives 17, 34, 35. However, the cushion body 1 may have a different type of adhesive from the elastic adhesive. The cushion body 1 may have, for example, a water-soluble adhesive. Similarly, instead of having elastic adhesives 34A, 35A, the cushion body 1A may have an adhesive different from the elastic adhesive. The cushion body 1A may have, for example, a water-soluble adhesive. In the method for manufacturing the cushion body described above, a water-soluble adhesive may be used instead of using the elastic adhesives 34, 35.

[0121] The cushion body 1 may be provided with a plurality of slits penetrating from the upper surface 1a to the lower surface 1b. The cushion body 1A may be provided with a plurality of slits penetrating from the upper surface 1Aa to the lower surface 1Ab. A sheet for adjusting the height of the cushion body 1A in the third direction D3 may be inserted below the lower surface 1Ab of the cushion body 1A.

[0122] In the method for manufacturing the cushion body described above, the cutting line L1 was constituted by a smooth curve when viewed from the side surface of the block body B. However, the cutting line L1 may be a line constituted by connecting a plurality of straight portions. The same applies to the cutting line L2.

[0123] The cushion body 1 can continue to provide a comfortable sleeping experience for the user even when the amount of weight fluctuation of a single user is large. However, when a plurality of users use the cushion body 1 at different times, even if there is a large difference between the minimum weight among the weights of the plurality of users and the maximum weight among the weights of the plurality of users, the cushion body 1 can continue to provide a comfortable sleeping experience for each of the plurality of users. Based on such an effect of the cushion body 1, the cushion body 1 can be used in various places such as accommodation facilities.

Explanation of Signs

[0124] 1, 1A... cushion body, 1a, 1Aa... upper surface, 1b, 1Ab... lower surface, 1c, 1Ad... short side, 1d, 1Ac... long side, 11, 11A... convex portion, 11Aa... upper surface, 12, 12A... concave portion, 13, 13A... upper layer member, 14, 14A... lower layer member, 14a, 14Aa... upper surface, 14b... lower surface, 15, 15A... convex portion, 15a, 15Aa... upper surface, 16, 16A... concave portion, 17, 34, 34A, 35, 35A... elastic adhesive, 31, 31A... first layer, 31b, 31Ab... lower surface, 32, 32A... second layer, 32a, 32Aa... upper surface, 32b, 32Ab... lower surface, 33, 33A... third layer, 33a, 33Aa... upper surface, 33b, 33Ab... lower surface, B... block body, D... device, D1... first direction, D2... second direction, D3... third direction, D4... fourth direction, D5... fifth direction, L1, L2, L3... cutting line, Lp1, Lp2... top, M... base material, M14... lower layer member, M14a... upper surface, M14A... lower layer member, M14b... lower surface, M15... convex portion, M16... concave portion, M31... first layer, M31b... lower surface, M32... second layer, M32a... upper surface, M32b... lower surface, M33... third layer, M33a... upper surface, R1, R2, R3... roll, s... gap.

Claims

1. Comprising a lower member and an upper member laminated on the lower member, The upper member has a third layer, a second layer laminated on the third layer, and a first layer laminated on the second layer, The upper member has an uneven structure extending from the first layer to the third layer, The lower member has an uneven structure that contacts the third layer, The lower member includes a plurality of convex portions that constitute the uneven structure of the lower member, The convex portion includes an upper surface that is in surface contact with the lower surface of the third layer, The hardness of the material constituting the first layer and the hardness of the material constituting the third layer are each lower than the hardness of the material constituting the second layer and the hardness of the material constituting the lower member, A cushion body in which the resilience of the material constituting the first layer and the resilience of the material constituting the third layer are each higher than the resilience of the material constituting the second layer and the resilience of the material constituting the lower member.

2. The lower surface of the first layer is bonded to the upper surface of the second layer by an elastic adhesive, The cushion body according to claim 1, wherein the lower surface of the second layer is bonded to the upper surface of the third layer by an elastic adhesive.

3. The cushion body according to claim 1 or claim 2, wherein the material constituting the first layer is the same as the material constituting the third layer.

4. The cushion body according to claim 1 or claim 2, wherein the material constituting the second layer is the same as the material constituting the lower member.

5. A step of producing a block body including the first layer, the second layer, and the third layer by laminating a second layer in the form of a plate on a third layer in the form of a plate and laminating a first layer in the form of a plate on the second layer; A step of producing an upper member having an uneven structure by cutting the block body along a cutting line that meanders so as to reciprocate from the first layer to the third layer; A step of forming an uneven structure on a lower member in the form of a plate; And a step of attaching the uneven structure of the lower member to the third layer, The hardness of the material constituting the first layer and the hardness of the material constituting the third layer are each lower than the hardness of the material constituting the second layer and the hardness of the material constituting the lower member, A method for manufacturing a cushion body, wherein the resilience of the material constituting the first layer and the resilience of the material constituting the third layer are each higher than the resilience of the material constituting the second layer and the resilience of the material constituting the lower layer member.

6. The step of producing the block body includes a step of bonding the upper surface of the second layer to the lower surface of the first layer with an elastic adhesive, and a step of bonding the upper surface of the third layer to the lower surface of the second layer with an elastic adhesive. The method for manufacturing a cushion body according to claim 5, wherein in each of the step of bonding the upper surface of the second layer and the step of bonding the upper surface of the third layer, the hardness of the upper layer member is adjusted by adjusting the amount of the elastic adhesive.

7. The step of forming the concavo-convex structure on the lower layer member includes a step of forming the upper surface of the convex portion by cutting each of the plurality of convex portions constituting the concavo-convex structure of the lower layer member along the lower surface of the third layer. In the step of attaching the lower layer member to the third layer, the surface of the third layer opposite to the second layer is bonded to the upper surface of the convex portion. The method for manufacturing a cushion body according to claim 5 or claim 6.

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