Mattress

Abstract

To provide a mattress for improving manufacturability.SOLUTION: A mattress includes: a first layer; and a second layer to be overlapped with the first layer. A first opposing surface opposing to the second layer in the first layer has a first recessed / projected structure. A second opposing surface opposing to the first layer in the second layer has a second recessed / projected structure. The second recessed / projected structure is fitted to the first recessed / projected structure so as to regulate a movement of the first layer in a first direction with respect to the second layer at a plurality of positions in the first direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE INVENTION An embodiment of the present invention relates to a mattress. [Background technology]

[0002] Conventionally, mattresses with a laminated structure in which multiple layers are stacked have been used. By stacking multiple layers, for example, the hardness and elasticity of the mattress can be adjusted, thereby improving sleeping comfort. During the manufacturing process of such mattresses, it can be very time-consuming to stack the layers together so that they do not shift relative to one another, and it can also be time-consuming to disassemble the stacked layers when disposing of the mattress. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-212848 Summary of the Invention [Problem to be solved by the invention]

[0004] An object of embodiments of the present invention is to provide a mattress that allows for improved manufacturability. [Means for solving the problem]

[0005] The mattress according to the embodiment includes a first layer and a second layer that is layered on the first layer. A first opposing surface of the first layer that faces the second layer has a first uneven structure. A second opposing surface of the second layer that faces the first layer has a second uneven structure. The second uneven structure fits into the first uneven structure and restricts movement of the first layer relative to the second layer in the first direction at a plurality of positions in the first direction. [Effects of the Invention]

[0006] According to an embodiment of the present invention, a mattress that can be manufactured with improved manufacturability can be provided. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic perspective view illustrating a mattress according to an embodiment. [Figure 2] FIG. 2 is a schematic exploded perspective view illustrating the mattress according to the embodiment. [Figure 3] 3(a) and 3(b) are schematic plan views illustrating the first layer of the mattress according to the embodiment. [Figure 4] 4(a) and 4(b) are schematic plan views illustrating the second layer of the mattress according to the embodiment. [Figure 5] 5(a) and 5(b) are schematic diagrams illustrating mattresses according to reference examples. [Figure 6] 6(a) and 6(b) are photographs illustrating a part of a mattress according to an embodiment. [Figure 7] 7(a) to 7(c) are schematic views illustrating a method for manufacturing a mattress according to an embodiment. [Figure 8] 8(a) and 8(b) are schematic plan views illustrating mattresses according to modified examples of the embodiment. [Figure 9] 9(a) to 9(d) are schematic diagrams illustrating mattresses according to modified examples of the embodiment. [Figure 10] 10(a) to 10(d) are schematic diagrams illustrating mattresses according to modified examples of the embodiment. [Figure 11] 11(a) and 11(b) are schematic diagrams illustrating a mattress according to a modified example of the embodiment. [Figure 12] FIG. 12 is a schematic view illustrating a mattress according to a modified example of the embodiment. [Figure 13] FIG. 13 is a schematic view illustrating a mattress according to a modified example of the embodiment. [Figure 14]FIG. 14 is a schematic view illustrating a mattress according to a modified example of the embodiment. [Figure 15] FIG. 15 is a schematic view illustrating a mattress according to a modified example of the embodiment. [Figure 16] FIG. 16 is a schematic view illustrating a mattress according to a modified example of the embodiment. [Figure 17] 17(a) and 17(b) are photographs illustrating mattresses according to modified embodiments. [Figure 18] 18(a) to 18(d) are schematic side views illustrating mattresses according to modified examples of the embodiment. [Figure 19] 19(a) to 19(d) are schematic diagrams illustrating mattresses according to modified examples of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between parts, etc. are not necessarily the same as those in reality. Even when the same part is shown, the dimensions and ratios may be different depending on the drawing. In this specification and in each drawing, elements similar to those previously described with reference to the previous drawings are designated by the same reference numerals, and detailed descriptions thereof will be omitted where appropriate.

[0009] FIG. 1 is a schematic perspective view illustrating a mattress according to an embodiment. As shown in FIG. 1 , a mattress 101 according to an embodiment has a first layer 10 and a second layer 20 that is layered on the first layer 10. For example, the first layer 10 is the upper layer and the second layer 20 is the lower layer, but the first layer 10 may be the lower layer and the second layer 20 may be the upper layer. In this example, the mattress 101 has a two-layer structure of the first layer 10 and the second layer 20, but the mattress 101 may have a laminated structure of three or more layers. The number of layers in the mattress according to an embodiment may be any number equal to or greater than two.

[0010] FIG. 2 is a schematic exploded perspective view illustrating the mattress according to the embodiment. FIG. 2 shows the mattress 101 in an exploded state, with the first layer 10 and the second layer 20 separated.

[0011] The first layer 10 has a first opposing surface 10f and a first outer surface 10e. The first opposing surface 10f is the surface that faces the second layer 20. The first outer surface 10e is the surface opposite to the first opposing surface 10f. For example, the first outer surface 10e is the top surface of the mattress 101, and a user lies on the first outer surface 10e.

[0012] The second layer 20 has a second opposing surface 20f and a second outer surface 20e. The second opposing surface 20f is the surface facing the first layer 10. The second outer surface 20e is the surface opposite the second opposing surface 20f. For example, the second outer surface 20e is the bottom surface of the mattress 101. The first layer 10 and the second layer 20 are stacked such that the first opposing surface 10f and the second opposing surface 20f face each other.

[0013] In the description of the embodiments, the direction from the second layer 20 to the first layer 10 is defined as the Z direction. The Z direction is the thickness direction of the mattress 101 (first layer 10 and second layer 20). The direction perpendicular to the Z direction is defined as the X direction, and the direction perpendicular to the Z direction and the X direction is defined as the Y direction. The first opposing surface 10f and the second opposing surface 20f are surfaces extending along the XY plane. The Y direction (an example of the first direction) is, for example, the longitudinal direction of the mattress 101 (first layer 10 and second layer 20). The X direction (an example of the second direction) is, for example, the lateral direction of the mattress 101 (first layer 10 and second layer 20).

[0014] 3(a) and 3(b) are schematic plan views illustrating the first layer of the mattress according to the embodiment. FIG. 3(a) shows the first opposing surface 10f of the first layer 10. The first opposing surface 10f includes a pair of side regions 10fs. One side region 10fs is located on one side of the first opposing surface 10f, and the other side region 10fs is located on the other side of the first opposing surface 10f opposite the one side. For example, each side region 10fs is a region that includes a long side of the first opposing surface 10f. The side region 10fs extends along the long side of the first opposing surface 10f from one short side to the other short side of the first opposing surface 10f.

[0015] Furthermore, the first opposing surface 10f includes a central region 10fc. The central region 10fc is located closer to the center of the first opposing surface 10f than the side regions 10fs. The central region 10fc is located between a pair of side regions 10fs and is adjacent to each side region 10fs. The central region 10fc extends from one short side to the other short side of the first opposing surface 10f.

[0016] The first opposing surface 10f has a concave-convex structure (first concave-convex structure 11). The concave-convex structure refers to a structure provided with at least either concave portions or convex portions. For example, the first concave-convex structure 11 has a plurality of convex portions 13. The plurality of convex portions 13 are arranged at a plurality of positions in the Y direction.

[0017] For example, the first concave-convex structure 11 (plurality of convex portions 13) is provided in at least a part of the side region 10fs. Fig. 3(b) is an enlarged view of a part of the side region 10fs of the first opposing surface 10f. The central region 10fc is flatter than the side region 10fs. The central region 10fc is an area where, for example, the concave-convex structure (plurality of convex portions 13) is not provided.

[0018] 4(a) and 4(b) are schematic plan views illustrating the second layer of the mattress according to the embodiment. FIG. 4(a) shows the second opposing surface 20f of the second layer 20. The second opposing surface 20f has a structure similar to that of the first opposing surface 10f described above. That is, for example, the second opposing surface 20f includes a pair of side regions 20fs and a central region 20fc. The side regions 20fs are regions that face the side regions 10fs (see FIG. 3(a)) of the first opposing surface 10f. The central region 20fc is a region that faces the central region 10fc (see FIG. 3(a)) of the first opposing surface 10f.

[0019] The second opposing surface 20f has a concave-convex structure (second concave-convex structure 21). For example, the second concave-convex structure 21 has a plurality of convex portions 23. The plurality of convex portions 23 are arranged at a plurality of positions in the Y direction.

[0020] For example, the second concave-convex structure 21 (plurality of convex portions 23) is provided in at least a part of the side region 20fs. Fig. 4(b) is an enlarged view of a part of the side region 20fs of the second opposing surface 20f. The central region 20fc is flatter than the side region 20fs. The central region 20fc is an area where, for example, the concave-convex structure (plurality of convex portions 23) is not provided.

[0021] The second uneven structure 21 fits into the first uneven structure 11 (see FIG. 3(a)) of the first layer 10. For example, in the XY plane, the convex portions 23 of the second uneven structure 21 are provided at positions shifted from the positions of the convex portions 13 of the first uneven structure 11. This causes the first uneven structure 11 and the second uneven structure 21 to mesh with each other (see FIG. 1).

[0022] Here, "fitting" refers to a state in which, when the first layer 10 and the second layer 20 are stacked, the convex portions of one concave-convex structure fit inside the concave portions of the other concave-convex structure (for example, between convex portions). Fitting is not limited to the convex portions of one concave-convex structure fitting snugly into the concave-convex structure of the other, but also includes the convex portions of one concave-convex structure fitting loosely into the concave-convex structure of the other. That is, when the convex portions of one concave-convex structure fit into the concave portions of the other concave-convex structure (for example, between convex portions), the position of the convex portions may be changeable relative to the concave portions. There may be play (gaps) between the convex portions that fit inside the concave portions and the concave portions.

[0023] The second uneven structure 21 restricts movement of the first layer 10 relative to the second layer 20 in at least the Y direction at multiple positions in the Y direction. More specifically, each of the convex portions 13 of the first layer 10 fits into the second uneven structure 21. As a result, for example, when the mattress 101 is curved in the Y direction, each of the convex portions 13 of the first layer 10 engages with the second uneven structure 21 (convex portions 23) in the Y direction. For example, the convex portions 13 come into contact with the side surfaces of the convex portions 23 in the Y direction. The second uneven structure 21 restricts movement of each of the convex portions 13 relative to the second layer 20 in the Y direction. Similarly, the first uneven structure 11 restricts movement of each of the convex portions 23 relative to the first layer 10 in the Y direction.

[0024] In this way, the positions of the first uneven structure 11 and the second uneven structure 21 can be prevented from shifting relative to each other in the Y direction. In the mattress according to the embodiment, by overlapping the first layer 10 and the second layer 20 so that the uneven structures fit together, the first layer 10 and the second layer 20 can be easily combined while preventing the first layer 10 and the second layer 20 from shifting positions. In addition, the combined first layer 10 and second layer 20 can be easily disassembled. This improves the manufacturability and disposability of the mattress.

[0025] For example, one possible method is to fasten the stacked layers together using hook-and-loop fasteners or adhesives to prevent misalignment. However, using adhesives requires a process of applying the adhesive and time for the adhesive to harden, increasing the number of steps. Furthermore, it may be difficult to separate the bonded layers when disposing of the mattress. Furthermore, it is difficult to replace only a layer that has deteriorated or become soiled. Using hook-and-loop fasteners requires a new component, increasing the number of steps. In contrast, the mattress 101 according to this embodiment can prevent misalignment between the first layer 10 and the second layer 20 without using hook-and-loop fasteners or adhesives to connect the first layer 10 and the second layer 20.

[0026] For example, an elastic material such as urethane can be used for the material of the first layer 10 and the material of the second layer 20. In this case, the engagement between the first uneven structure 11 and the second uneven structure 21 may cause deformation of the convex portions 13 and 23, but misalignment between the first layer 10 and the second layer 20 is suppressed.

[0027] As described above, the first concave-convex structure 11 is provided in the side region 10fs, and the second concave-convex structure 21 is provided in the side region 20fs. By interlocking the concave-convex structures at the ends of the first layer 10 and the second layer 20, overall misalignment can be suppressed. For example, if the concave-convex structure is provided over a wide range, it may be difficult to interlock all of the concave-convex structures if distortion occurs in the concave-convex structures due to processing. In contrast, the central regions 10fc, 20fc are flat and have no convex portions, so the range in which the concave-convex structures interlock is limited. This makes it easy to combine the first layer 10 and the second layer 20 by interlocking the concave-convex structures.

[0028] For example, the width of the side regions 10fs in the X direction is narrower than the width of the central region 10fc in the X direction. In this way, the side regions 10fs are narrower than the central region 10fc, so that the range in which the recesses and protrusions fit together is further limited.

[0029] As shown in FIG. 3(a), in this example, the first uneven structure 11 is continuous from one end to the other end of the first layer 10 in the Y direction in the side region 10fs. In other words, the first uneven structure 11 is provided throughout the entire side region 10fs. A plurality of convex portions 13 are periodically arranged throughout the entire side region 10fs. Similarly, as shown in FIG. 4(a), a plurality of convex portions 23 of the second uneven structure 21 are periodically arranged throughout the entire side region 20fs. This, for example, can further suppress misalignment between the first layer 10 and the second layer 20.

[0030] In this example, the first concave-convex structure 11 and the second concave-convex structure 21 are prevented from shifting relative to each other not only in the Y direction but also in the X direction. For example, the second concave-convex structure 21 comes into contact with each of the convex portions 13 of the first concave-convex structure 11, thereby restricting movement of each of the convex portions 13 relative to the second layer 20 in the X and Y directions.

[0031] As a more specific example, as shown in FIG. 3(a), multiple protrusions 13 are arranged side by side in the X and Y directions. Multiple protrusions 13 of the same shape are arranged at a constant first period in the Y direction and at a constant second period in the X direction. The multiple protrusions 13 are arranged, for example, in a staggered pattern. That is, the position of the protrusion 13 closest to one protrusion 13 is shifted from the position of the other protrusion 13 by 1 / 2 pitch (half the first period) in the Y direction and by 1 / 2 pitch (half the second period) in the X direction. In this example, the multiple protrusions 13 are arranged in an island shape, separated from each other, and independent.

[0032] Each of the protrusions 13 has, for example, a conical or truncated conical shape with a rounded apex. As shown in Fig. 3(b), the side surfaces of the protrusions 13 include an X-direction side surface 13x (a side surface facing the X direction or the opposite direction) and a Y-direction side surface 13y (a side surface facing the Y direction or the opposite direction).

[0033] 4(a), in the second layer 20, a plurality of protrusions 23 are arranged corresponding to the plurality of protrusions 13 in the first layer 10. That is, the plurality of protrusions 23 are arranged in the X direction and the Y direction. The plurality of protrusions 23 having the same shape are arranged at a first constant period in the Y direction and at a second constant period in the X direction. The plurality of protrusions 23 are arranged, for example, in a staggered pattern.

[0034] 4(b), the side surfaces of the protrusion 23 include a side surface 23x in the X direction and a side surface 23y in the Y direction. The shape of the protrusion 23 may be the same as the shape of the protrusion 13.

[0035] When the protrusions 13 of the first concave-convex structure 11 are fitted into the second concave-convex structure 21, the movements of the protrusions 13 in the X and Y directions are restricted by the protrusions 23 located around the protrusions 13. That is, the X-direction side surface 13x of the protrusions 13 faces the X-direction side surface 23x of the protrusions 23, and the side surface 13x contacts and engages with the side surface 23x, thereby restricting the X-direction movement of the protrusions 13. The Y-direction side surface 13y of the protrusions 13 faces the Y-direction side surface 23y of the protrusions 23, and the side surface 13y contacts and engages with the side surface 23y, thereby restricting the Y-direction movement of the protrusions 13. Similarly, the X-direction and Y-direction movements of the protrusions 23 are restricted by the protrusions 13.

[0036] The height of the convex portions of the first uneven structure 11 is, for example, 10 mm to 40 mm, and preferably 20 mm to 30 mm, which makes it easier to fit the first uneven structure 11 and the second uneven structure 12 together and effectively prevents misalignment between the layers.

[0037] 5(a) and 5(b) are schematic diagrams illustrating mattresses according to reference examples. As shown in Fig. 5(a), in the mattress 190 of the reference example, a first layer 91 and a second layer 92 are stacked on top of each other. The first layer 91 and the second layer 92 are not fastened together with hook-and-loop fasteners or adhesive. The first layer 91 and the second layer 92 do not have a recessed and protruding structure that fits together.

[0038] FIG. 5(b) illustrates an example of "raising the back" of a mattress. In raising the back, the mattress is bent so that the long sides of the mattress are curved. When raising the back of the mattress 190, for example, the first layer 91 and the second layer 92 bend in different ways (curvatures). When the relative positions of the first layer 91 and the second layer 92 shift, a shift M occurs, for example, at the end of the mattress. In contrast, in the embodiment, as described above, the first uneven structure 11 and the second uneven structure 21 suppress misalignment in the Y direction (longitudinal direction). That is, it is possible to suppress misalignment between the first layer 10 and the second layer 20 when raising the back.

[0039] 6(a) and 6(b) are photographs illustrating a part of a mattress according to an embodiment. Fig. 6(a) shows mattress 101 before the back is raised. Fig. 6(b) shows mattress 101 when the back is raised. When the back is raised, convex portion 13 and convex portion 23 engage with each other, thereby preventing the layers of mattress 101 from shifting in the longitudinal direction.

[0040] In this example, the first layer 10 has a laminated structure of an outer layer 10p and an inner layer 10q. The inner layer 10q is located between the outer layer 10p and the second layer 20. The inner layer 10q includes a first opposing surface 10f on which a protrusion 13 is provided. For example, the inner layer 10q is softer than the outer layer 10p. In other words, the outer layer 10p is harder than the inner layer 10q. The hardness is evaluated, for example, using the "40% hardness" defined in "JIS K 6400-2 A Method."

[0041] Because the inner layer 10q is relatively soft, the first uneven structure 11 (protrusions 13) can deform when the mattress is bent, for example, when the back is raised. This absorbs, for example, the difference in the bending of the first layer 10 and the second layer 20. Similarly, the second layer 20 may have a laminated structure of the outer layer 20p and the inner layer 20q. The inner layer 20q may be softer than the outer layer 20p.

[0042] 7(a) to 7(c) are schematic views illustrating a method for manufacturing a mattress according to an embodiment. The first layer 10 and the second layer 20 can be formed by, for example, profile processing. For example, as shown in FIG. 7(a), a mat material 100 such as urethane foam is sandwiched between two rollers R from above and below. The surface of the rollers R is provided with irregularities that form a first uneven structure 11 and a second uneven structure 12. The mat material 100 is compressed by the irregularities of the rollers R.

[0043] The compressed portion of the mat material 100 is cut into upper and lower parts by rotating the roller R, while changing the position where the mat material 100 is compressed. As a result, as shown in Fig. 7(b), a mat layer 100a that will become the first layer 10 (or a part of the first layer 10) and a mat layer 100b that will become the second layer 20 (or a part of the second layer 20) are formed from the mat material 100. The surface of the mat layer 100a has irregularities that will become the first uneven structure 11, and the surface of the mat layer 100b has irregularities that will become the second uneven structure 21.

[0044] As shown in Fig. 7(c), for example, the mat layer 100a is cut at its short-side end to form a pair of side portions 10s and a central portion 10c. The side portions 10s include the side regions 10fs of the first opposing surface 10f described with reference to Fig. 3(a). The central portion 10c includes the central region 10fc of the first opposing surface 10f described with reference to Fig. 3(a).

[0045] The side portion 10s, with its uneven surface (i.e., the first uneven structure 11) facing downward, is bonded to the end of the central portion 10c, with its surface without unevenness (i.e., the flat central region 10fc) facing downward. As a result, as described with reference to FIG. 3(a), the first layer 10 is formed, with the first opposing surface 10f having unevenness in the side region 10fs. For example, the boundary between the side region 10fs and the central region 10fc is the bonding surface.

[0046] The upper surface of the side portion 10s, i.e., the surface opposite to the first opposing surface 10f, is flatter than the first uneven structure 11. The upper surface of the central portion 10c is uneven. This can improve the sleeping comfort of the mattress, for example. The convex portions on the upper surface of the central portion 10c may have a shape different from the convex portions 13 of the first uneven structure 11. Similarly, the second layer 20 can be formed from the mat layer 100b.

[0047] By using profile processing, the first uneven structure 11 and the second uneven structure 12 can be formed, for example, from a single piece of urethane foam. This makes it easier for the first uneven structure 11 and the second uneven structure 12 to fit together. However, in the embodiment, the first layer 10 and the second layer 20 do not necessarily have to be formed by profile processing. For example, two-dimensional processing using an NC machine tool may be used.

[0048] 8(a) and 8(b) are schematic plan views illustrating mattresses according to modified examples of the embodiment. FIG. 8(a) shows the first opposing surface 10f of the first layer 10, and FIG. 8(b) shows the second opposing surface 20f of the second layer 20. As shown in FIG. 8(a), in this example, the side region 10fs has a concave-convex region s11 and a flat region s12. The concave-convex region s11 is a region in which the first concave-convex structure 11 is provided. The flat region s12 is a region that is flatter than the concave-convex region s11, and is, for example, a region in which no concave-convex structure is provided. The concave-convex regions s11 and the flat region s12 are arranged alternately in the Y direction. The concave-convex regions s11 are provided at both ends and the center of the side region 10fs in the Y direction.

[0049] Similarly, as shown in FIG. 8(b), the side region 20fs has a concave-convex region s21 in which the second concave-convex structure 12 is provided, and a flat region s22 that is flatter than the concave-convex region s21.

[0050] In this way, the first concave-convex structure 11 and the second concave-convex structure 21 may be provided partially in a part of the side region 10fs and a part of the side region 20fs, respectively. This further limits the range in which the concaves and convexes fit together when the first layer 10 and the second layer 20 are stacked. For example, it becomes easier to combine the first layer 10 and the second layer 20 by fitting the concaves and convexes together.

[0051] 9(a) to 9(d) are schematic diagrams illustrating mattresses according to modified examples of the embodiment. Fig. 9(a) is a schematic plan view showing a part of the first concavo-convex structure 11 provided in the side region 10fs, and Fig. 9(b) is a cross-sectional view taken along line A1-A1 shown in Fig. 9(a). Fig. 9(c) is a schematic plan view showing a part of the second concavo-convex structure 21 provided in the side region 20fs. Fig. 9(d) is a cross-sectional view taken along line A2-A2 shown in Fig. 9(c). The example of FIGS. 9(a) to 9(d) is similar to the mattress 101 described above, except for the shapes of the first concave-convex structure 11 and the second concave-convex structure 12.

[0052] As shown in Figures 9(a) and 9(b), the first uneven structure 11 has a plurality of convex portions 13a and a plurality of concave portions 14a. The shapes of the plurality of convex portions 13a may be the same as each other. The shapes of the plurality of concave portions 14a may be the same as each other. The convex portions 13a and the concave portions 14a are alternately arranged at a constant period in the X direction and alternately arranged at a constant period in the Y direction. The plurality of convex portions 13 are arranged, for example, in a staggered pattern.

[0053] The protrusions 13a are, for example, quadrangular prism-shaped. As shown in Fig. 9(a), the corners of the protrusions 13a may be in contact with the corners of adjacent protrusions 13a in a plan view. For example, the protrusions in the first uneven structure 11 may be connected to each other. In other words, the multiple protrusions may each be part of a single continuous protrusion shape.

[0054] 9(c) and 9(d), the second concave-convex structure 12 has a plurality of convex portions 23a and a plurality of concave portions 24a. The convex portions 13a and the convex portions 23a may have the same shape.

[0055] The protrusions 13a fit into the recesses 24a, and the protrusions 23a fit into the recesses 14a, thereby preventing misalignment between the first layer 10 and the second layer 20 in the X and Y directions.

[0056] 10(a) to 10(d) are schematic diagrams illustrating mattresses according to modified examples of the embodiment. Fig. 10(a) is a schematic plan view showing a part of the first concavo-convex structure 11 provided in the side region 10fs, and Fig. 10(b) is a cross-sectional view taken along line A3-A3 shown in Fig. 10(a). Fig. 10(c) is a schematic plan view showing a part of the second concavo-convex structure 21 provided in the side region 20fs. Fig. 10(d) is a cross-sectional view taken along line A4-A4 shown in Fig. 10(c). The example of FIGS. 10(a) to 10(d) is similar to the mattress 101 described above, except for the shapes of the first concave-convex structure 11 and the second concave-convex structure 12.

[0057] 10(a) and 10(b), the first uneven structure 11 has a plurality of convex portions 13b having the same shape and a plurality of concave portions 14b having the same shape. The convex portions 13b and the concave portions 14b are alternately arranged at a constant interval in the Y direction.

[0058] The peaks t (ridges) of the protrusions 13b extend in directions that intersect with the X and Y directions. For example, the peaks t extend in the X direction while bending in a zigzag pattern. The side surfaces 13bs of the protrusions 13b are inclined surfaces that are inclined with respect to the X, Y, and Z directions.

[0059] 10(c) and 10(d), the second concave-convex structure 12 has a plurality of convex portions 23b and a plurality of concave portions 24b. The convex portions 13b and the convex portions 23b may have the same shape. The convex portions 23b have side surfaces 23bs that are inclined with respect to the X, Y, and Z directions.

[0060] When the protrusion 13b fits into the recess 24b, the side surface 13bs of the protrusion 13b faces the side surface 23bs of the protrusion 23b adjacent to the protrusion 13b in the Y direction. The side surfaces 13bs and 23bs come into contact and engage with each other, restricting the movements of the protrusions 13 and 23 in the X and Y directions.

[0061] 11(a), 11(b), 12, and 13 are schematic diagrams illustrating mattresses according to modified embodiments. Fig. 11(a) is a perspective view illustrating a mattress 102 according to an embodiment. Fig. 11(b) is a cross-sectional view taken along line A5-A5 in Fig. 11(a). The mattress 102 may be similar to the mattress 101 described above, except for the shapes of the first uneven structure 11 and the second uneven structure 12.

[0062] FIG. 12 is a perspective view illustrating the side region 10fs of the first layer 10 of the mattress 102. The first uneven structure 11 provided in the side region 10fs has multiple convex portions 13c aligned in the Y direction. Each convex portion 13c has a cylindrical portion with a conical portion connected to the tip. The diameter of the base of the conical portion is larger than the diameter of the cylindrical portion. In other words, the width of each convex portion 13c increases toward the tip and then decreases.

[0063] 13 is a perspective view illustrating the side region 20fs of the second layer 20 of the mattress 102. The second concavo-convex structure 21 provided in the side region 20fs has a plurality of recesses 24c aligned in the Y direction.

[0064] The position and shape of the recesses 24c correspond to the position and shape of the protrusions 13c shown in Figure 12. Each protrusion 13c fits into each recess 24c. The side surfaces of the protrusions 13c come into contact with the inner surfaces of the recesses 24c, restricting movement of the protrusions 13c in the X and Y directions relative to the recesses 24c. This makes it possible to suppress misalignment between the first layer 10 and the second layer 20 in the X and Y directions. Such a concave-convex structure can be formed, for example, by two-dimensional processing.

[0065] 14, 15 and 16 are schematic diagrams illustrating mattresses according to modified embodiments. 14 is a perspective view illustrating a mattress 103 according to an embodiment. The mattress 103 may be similar to the mattress 101 described above, except for the shapes of the first uneven structure 11 and the second uneven structure 12.

[0066] 15 is a perspective view illustrating the first layer 10 of the mattress 103. The first uneven structure 11 has a plurality of convex portions 13d aligned in the Y direction. The side surfaces 13ds of the convex portions 13d are inclined with respect to the Z and Y directions and extend in the X direction. The convex portions 13d are shaped so that their width in the Y direction increases toward their tips.

[0067] FIG. 16 is a perspective view illustrating the second layer 20 of the mattress 103. The second uneven structure 21 has a plurality of recesses 24d aligned in the Y direction. The positions and shapes of the recesses 24d correspond to the positions and shapes of the protrusions 13d shown in FIG. 14. Each protrusion 13d fits into each recess 24d. By increasing the width of the protrusions 13d toward the tip, for example, movement of the protrusions 13d relative to the recesses 24d is further suppressed.

[0068] 17(a) and 17(b) are photographs illustrating mattresses according to modified embodiments. The first uneven structure 11 has a plurality of protrusions 13e aligned in the Y direction. The side surfaces of the protrusions 13e are inclined with respect to the Z and Y directions and extend in the X direction. The protrusions 13e are mountain-shaped, with their width in the Y direction narrowing toward their tips. The ridges of the mountains extend in the X direction.

[0069] The second concave-convex structure 21 has a plurality of recesses 24e aligned in the Y direction. The positions and shapes of the recesses 24e correspond to the positions and shapes of the protrusions 13e. Each protrusion 13e fits into each recess 24e, thereby suppressing misalignment between the first layer 10 and the second layer 20. The concave-convex structure described with reference to FIGS. 14 to 17(b) can be formed by, for example, two-dimensional processing.

[0070] 18(a) to 18(d) are schematic side views illustrating mattresses according to modified examples of the embodiment. In the mattress 104 according to this embodiment, the first layer 10 and the second layer 20 are also laminated. Figure 18(a) shows the first layer 10 and the second layer 20 disassembled, and Figure 18(b) shows the first layer 10 and the second layer 20 combined together.

[0071] As shown in FIG. 18(a), a first uneven structure 11 is provided in a side region 10fs of a first opposing surface 10f of the first layer 10. As will be described later, the first uneven structure 11 has concave and convex portions aligned in the Y direction. The first opposing surface 10f has a first step 17. The first step 17 is provided at a position different from that of the first uneven structure 11. In other words, the first step 17 is a step separate from the convex and concave portions of the first uneven structure 11. In this example, the first step 17 is located at the boundary between the side region 10fs and the central region 10fc. The side surface of the first step 17 intersects with the X direction and extends along the Y and Z directions. The first step 17 makes the side region 10fs a region recessed from the central region 10fc toward the opposite side to the second layer 20.

[0072] As shown in FIG. 18(a), a second uneven structure 21 is provided in the side region 20fs of the second opposing surface 20f of the second layer 20. As will be described later, the second uneven structure 21 has concave and convex portions aligned in the Y direction. The second opposing surface 20f has a second step 27 corresponding to the first step 17. The second step 27 is provided at a position different from that of the second uneven structure 21. In other words, the second step 27 is a step separate from the convex and concave portions of the second uneven structure 21. In this example, the second step 27 is located at the boundary between the side region 20fs and the central region 20fc. The side surface of the second step 27 intersects with the X direction and extends along the Y and Z directions. Due to the second step 27, the side region 20fs protrudes from the central region 20fc toward the first layer 10.

[0073] 18(b), the side surface of the second step 27 faces the side surface of the first step 17 and contacts the side surface of the first step 17. The second step 27 engages with the first step 17, thereby restricting movement of the first step 17 in the X direction relative to the second layer 20. In other words, the first step 17 and the second step 27 suppress misalignment between the first layer 10 and the second layer 20 in the X direction.

[0074] 18(c) and 18(d), the first layer 10 may have a first step 17 formed by a central portion and a separate member (side portion) having different thicknesses. The second layer 20 may have a second step 27 formed by a central portion and a separate member (side portion) having different thicknesses.

[0075] 19(a) to 19(d) are schematic diagrams illustrating mattresses according to modified examples of the embodiment. Figure 19(a) is a schematic plan view showing a portion of the first opposing surface 10f of the first layer 10 of the mattress 104 shown in Figure 18(a). Figure 19(b) is a cross-sectional view taken along line A6-A6 in Figure 19(a). Figure 19(c) is a schematic plan view showing a portion of the second opposing surface 20f of the second layer 20 of the mattress 104 shown in Figure 18(a). Figure 19(d) is a cross-sectional view taken along line A7-A7 shown in Figure 19(c).

[0076] 19(a) and 19(b), the first concavo-convex structure 11 has a plurality of convex portions 13f and a plurality of concave portions 14f. The convex portions 13f and the concave portions 14f are arranged alternately at a constant interval in the Y direction.

[0077] The side surfaces 13fs of each protrusion 13f are inclined with respect to the Y and Z directions and extend parallel to the X direction. The protrusions 13f are mountain-shaped, with their width in the Y direction narrowing toward their tips. The tops (ridges) of the protrusions 13f and the bottoms (valley bottoms) of the recesses 14f extend parallel to the X direction.

[0078] 19(c) and 19(d), the second concave-convex structure 12 has a plurality of convex portions 23f and a plurality of concave portions 24f. The convex portions 13f and the convex portions 23f may have the same shape. The side surfaces 23fs of each convex portion 23f are inclined with respect to the Y and Z directions and extend parallel to the X direction.

[0079] When the protrusion 13f fits into the recess 24f, the side surface 13fs of the protrusion 13f faces the side surface 23fs of the protrusion 23f adjacent to the protrusion 13f in the Y direction. The second uneven structure 21 (the side surface 23fs of the protrusion 23f) contacts and engages with the side surface 13fs of the protrusion 13f, thereby restricting movement of the protrusion 13f in the Y direction relative to the second layer 20.

[0080] In this way, the first uneven structure 11 and the second uneven structure 21 suppress misalignment in the Y direction between the first layer 10 and the second layer 20. In this example, the first uneven structure 11 and the second uneven structure 21 do not need to suppress misalignment in the X direction between the first layer 10 and the second layer 20. As already described with reference to Figures 18(a) and 18(b), misalignment in the X direction can be suppressed by the first step 17 and the second step 27. Such a first uneven structure 11 and second uneven structure 21 can be processed relatively easily.

[0081] The embodiment may include the following configurations (for example, technical solutions). (Configuration 1) A first layer and a second layer overlapping the first layer, a first opposing surface of the first layer opposing the second layer has a first uneven structure; A mattress in which a second opposing surface of the second layer facing the first layer has a second uneven structure that engages with the first uneven structure and restricts movement of the first layer relative to the second layer in the first direction at multiple positions in the first direction. (Configuration 2) 2. The mattress of claim 1, wherein the first direction is the longitudinal direction of the first layer. (Configuration 3) the first opposing surface includes a side region located on one side of the first opposing surface and a central region located closer to the center of the first opposing surface than the side region, the first uneven structure is provided in at least a part of the side region, 3. The mattress of configuration 1 or 2, wherein the central region is flatter than the side regions. (Configuration 4) A mattress as described in configuration 3, wherein the first uneven structure is continuous from one end to the other end of the first layer in the first direction in the side region. (Configuration 5) A mattress as described in configuration 3, wherein the side region has an uneven region in which the first uneven structure is provided and a flat region that is flatter than the uneven region. (Configuration 6) 6. The mattress of any one of configurations 3 to 5, wherein the side regions are narrower than the central region. (Configuration 7) the first opposing surface extends in the first direction and a second direction perpendicular to the first direction; the first uneven structure includes a plurality of convex portions arranged at a plurality of positions in the first direction, A mattress described in any one of configurations 1 to 6, wherein the second uneven structure contacts each of the plurality of convex portions to restrict movement of each of the plurality of convex portions in the first direction and the second direction relative to the second layer. (Configuration 8) the first opposing surface extends in the first direction and a second direction perpendicular to the first direction; the first uneven structure includes a plurality of convex portions arranged at a plurality of positions in the first direction, Each of the plurality of protrusions has a side surface extending in the second direction, the second uneven structure restricts movement of each of the plurality of protrusions relative to the second layer in the first direction by contacting the side surface; the first opposing surface has a first step provided at a position different from the first concave-convex structure, A mattress described in any one of configurations 1 to 6, wherein the second opposing surface has a second step that contacts the first step to restrict movement of the first step in the second direction relative to the second layer. (Configuration 9) the first layer includes an outer layer and an inner layer located between the outer layer and the second layer and including the first opposing surface; The mattress of any one of configurations 1 to 8, wherein the inner layer is softer than the outer layer.

[0082] The above-described embodiments are examples of realizing the present invention, and the present invention is not limited to these embodiments. For example, the present invention also includes embodiments in which some components are added, deleted, or modified in the above-described embodiments. [Explanation of symbols]

[0083] 10: 1st layer 10c: Central part 10e: 1st outer surface 10f: First opposing surface 10fc: central area 10fs: Side region 10p: Outer layer 10q: inner layer 10s: Side part 11: First uneven structure 12:Second uneven structure 13, 13a, 13b, 13c, 13d, 13e, 13f: convex parts 13bs, 13ds, 13fs, 13x, 13y: Side 14a, 14b, 14f: recesses 17: First step 20: 2nd layer 20e: 2nd outer surface 20f: 2nd facing surface 20fc: central area 20fs: Side region 20p: outer layer 20q: inner layer 21:Second uneven structure 23, 23a, 23b, 23f: convex parts 23bs, 23fs, 23x, 23y: side 24, 24a, 24b, 24c, 24d, 24e, 24f: recesses 27: Second step 91: 1st layer 92:Second layer 100: Matte material 100a, 100b: Matte layer 101~104, 190: Mattress M: Misalignment R: Laura s11, s21: uneven area s12, s22: flat area

Claims

1. A first layer and a second layer superimposed on the first layer, a first opposing surface of the first layer opposing the second layer has a first uneven structure; A mattress in which a second opposing surface of the second layer facing the first layer has a second uneven structure that engages with the first uneven structure and restricts movement of the first layer relative to the second layer in the first direction at multiple positions in the first direction.

2. The mattress of claim 1 , wherein the first direction is a longitudinal direction of the first layer.

3. the first opposing surface includes a side region located on one side of the first opposing surface and a central region located closer to the center of the first opposing surface than the side region, the first concave-convex structure is provided in at least a part of the side region, 3. The mattress of claim 1, wherein the central region is flatter than the side regions.

4. The mattress according to claim 3 , wherein the first uneven structure is continuous from one end to the other end of the first layer in the first direction in the side region.

5. The mattress according to claim 3 , wherein the side region has an uneven region in which the first uneven structure is provided and a flat region that is flatter than the uneven region.

6. The mattress of claim 3 , wherein the side regions are narrower than the central region.

7. the first opposing surface extends in the first direction and a second direction perpendicular to the first direction; the first uneven structure includes a plurality of convex portions arranged at a plurality of positions in the first direction, The mattress of claim 1 or 2, wherein the second uneven structure contacts each of the plurality of protrusions to restrict movement of each of the plurality of protrusions in the first direction and the second direction relative to the second layer.

8. the first opposing surface extends in the first direction and a second direction perpendicular to the first direction; the first uneven structure includes a plurality of convex portions arranged at a plurality of positions in the first direction, Each of the plurality of protrusions has a side surface extending in the second direction, the second uneven structure restricts movement of each of the plurality of protrusions relative to the second layer in the first direction by contacting the side surface; the first opposing surface has a first step provided at a position different from the first concave-convex structure, The mattress of claim 1 or 2, wherein the second opposing surface has a second step that contacts the first step to restrict movement of the first step in the second direction relative to the second layer.

9. the first layer includes an outer layer and an inner layer positioned between the outer layer and the second layer and including the first opposing surface; 3. The mattress of claim 1, wherein the inner layer is softer than the outer layer.

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