Compressed mattress and method for manufacturing the same

Abstract

To provide a compressed mattress capable of being excellently restored to a shape before compression when a storage bag is opened, and a method for manufacturing the same.SOLUTION: In a compressed mattress (1) in which a mattress main body (3) is compressed and stored in a storage bag (4) in a sealed manner in a state of being stored inside a cover (2) and wound in a roll shape, the mattress main body (3) is formed of a filament three-dimensional bonded body in which filaments are knitted in a front-back direction which is a height direction of a lying person, a right-left direction, and an up-down direction, and the front-back direction and the right-left direction orthogonal to a compression direction are harder than the up-down direction which is the compression direction. An upper surface (6) and / or a lower surface (7) of the mattress main body (3) are made harder than an intermediate part (8) between the upper surface (6) and the lower surface (7). The upper surface (6) or the lower surface (7) of the mattress main body (3) on the outer side when wound in a roll shape is harder than the lower surface (7) or the upper surface (6) of the mattress min body (3) on the inner side.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a compressed mattress in which a mattress body is housed inside a cover, compressed and stored in a sealed storage bag, and then wound into a roll, and to a method for manufacturing such a compressed mattress. [Background technology]

[0002] Mattresses retain their elasticity and insulating properties by containing air inside, such as cotton or urethane. Therefore, mattresses can provide comfort to users by using them with air trapped inside.

[0003] On the other hand, the mattress becomes bulky when it is filled with air, which makes it difficult to transport the mattress.

[0004] Therefore, conventionally, it has been considered to compress and store a mattress in a storage bag (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-29501 Summary of the Invention [Problem to be solved by the invention]

[0006] In recent years, mattresses have been used as cushioning materials for their interiors, with the mattress body consisting of a three-dimensional assembly of filaments extending in the front-to-back direction (corresponding to the height of a person lying down), the left-to-right direction, and the up-to-down direction. In these conventional mattresses, the mattress body is formed by weaving filaments made of multiple molten thermoplastic resin fibers into a three-dimensional net shape, so that the density of the filaments is constant in the up-to-down direction, the front-to-back direction, and the left-to-right direction.

[0007] However, when the mattress body made of the above-mentioned three-dimensional filament bonded body is stored inside a cover, compressed and stored in a sealed storage bag, and then wound into a roll, a problem occurs in which the mattress body remains in its compressed shape and does not return to its original shape even when the storage bag is opened. [Means for solving the problem]

[0008] Therefore, in the present invention according to claim 1, in a compressed mattress in which the mattress body is stored inside a cover, compressed and stored in a storage bag in a sealed state, and then wound into a roll, the mattress body is made of a three-dimensional filament bond in which filaments are woven in the front-to-back direction, which corresponds to the height direction of a person lying down, as well as the left-to-right direction and the up-to-down direction, and the front-to-back and left-to-right directions, which are perpendicular to the compression direction, are harder than the up-to-down direction, which is the compression direction.

[0009] Furthermore, in the present invention according to claim 2, in the present invention according to claim 1, the upper surface and / or lower surface of the mattress body is made harder than the intermediate portion between the upper and lower surfaces.

[0010] Furthermore, in the present invention according to claim 3, in the present invention according to claim 2, the upper or lower surface of the mattress body that is on the outside when rolled up into a roll is made harder than the lower or upper surface of the mattress body that is on the inside.

[0011] Furthermore, in the present invention as claimed in claim 4, in a manufacturing method of a compressed mattress in which the mattress body is stored inside a cover, compressed and stored in a storage bag in a sealed state, and then wound into a roll, the mattress body is made of a three-dimensional filament bond in which filaments are woven in the front-to-back direction, which is the height direction of a person lying down, as well as the left-to-right direction and the up-to-down direction, and is harder in the front-to-back and left-to-right directions perpendicular to the compression direction than in the up-to-down direction, which is the compression direction, and the mattress body is compressed in the up-to-down direction and then wound into a roll. [Effects of the Invention]

[0012] The present invention provides the following effects.

[0013] In other words, in the present invention, in a compressed mattress and its manufacturing method, the mattress body is stored inside a cover, compressed and stored in a sealed storage bag, and wound into a roll.The mattress body is made of a three-dimensional filament bond in which filaments are woven in the front-to-back direction, which is the height direction of a person lying down, as well as the left-to-right direction and the up-to-down direction, and is made harder in the front-to-back and left-to-right directions perpendicular to the compression direction than in the up-to-down direction, which is the compression direction.Therefore, by opening the storage bag, the mattress body can be smoothly restored to its pre-compression shape.

[0014] In particular, if the upper and / or lower surfaces of the mattress body are made harder than the intermediate portion between the upper and lower surfaces, the mattress body can be restored to its pre-compression shape more effectively by opening the storage bag.

[0015] Furthermore, if the upper or lower surface of the mattress body, which is on the outside when rolled up, is made harder than the lower or upper surface of the mattress body, which is on the inside, it is possible to prevent the mattress body from becoming bent when the storage bag is opened to restore the mattress body to its pre-compression shape. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is an explanatory diagram showing a compressed mattress according to the present invention. [Figure 2] (a) is a side cross-sectional explanatory diagram showing the mattress body, and (b) is an enlarged explanatory diagram of the same part. [Figure 3] 1 is an explanatory diagram showing a method for manufacturing a compressed mattress. DETAILED DESCRIPTION OF THE INVENTION

[0017] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The specific configuration of the compressed mattress and the manufacturing method thereof according to the present invention will be described below with reference to the drawings.

[0018] As shown in FIG. 1, a compressed mattress 1 is a mattress body 3 housed inside a cover 2, compressed and stored in a sealed state in a storage bag 4, and then wound into a roll.

[0019] When the storage bag 4 of this compressed mattress 1 is opened, air enters the mattress body 3 inside the storage bag 4, and the mattress body 3 stored inside the cover 2 returns to its shape before compression, becoming a rectangular plate-shaped mattress 5.

[0020] The cover 2 is only required to be able to accommodate the rectangular plate-shaped mattress body 3, and is made of a flexible material (for example, cloth) that changes shape as the mattress body 3 is compressed. The cover 2 may be provided with an openable and closable zipper at the opening for attaching and detaching the mattress body 3.

[0021] As shown in Figure 2, the mattress body 3 is integrally formed as a whole from a three-dimensional filament assembly in which filaments are woven in the front-to-back direction (left-to-right in Figure 2), which corresponds to the height of a person lying down, as well as in the left-to-right and up-to-down directions, and is formed into a rectangular plate shape extending in the front-to-back direction, which corresponds to the height of a person lying down, and in the left-to-right and up-to-down directions perpendicular to the front-to-back direction. Here, the three-dimensional filament assembly is formed by dropping filaments made of multiple molten thermoplastic resin fibers from above, fusing the filaments together into a three-dimensional net-like shape, and then cooling the filaments. Thermoplastic resin materials such as polyethylene and polypropylene are used as the filaments.

[0022] This mattress body 3 has an upper surface 6, which is a layer formed in a planar shape on the upper side, and a lower surface 7, which is a layer formed in a planar shape on the lower side, between which is formed an intermediate portion 8, which is a layer that is thicker (longer in the vertical direction) than the upper surface 6 and the lower surface 7.

[0023] The upper surface 6 and the lower surface 7 have the same lengths as the intermediate portion 8 in the front-rear and left-right directions, but are shorter and thinner than the intermediate portion 8 in the up-down direction (thickness).

[0024] Furthermore, the upper surface 6 and the lower surface 7 have a higher filament density than the intermediate portion 8, so that the stiffness in the vertical direction is greater than that of the intermediate portion 8. Note that it is also possible to make only one of the upper surface 6 and the lower surface 7 have a higher filament density than that of the intermediate portion 8, so that the stiffness in the vertical direction is greater than that of the intermediate portion 8.

[0025] The upper surface 6 and the lower surface 7 may have the same filament density and the same hardness, but here, when the compressed mattress 1 is wound into a roll, the filament density on the side located on the outside of the roll (lower surface 7) is made higher than that on the side located on the inside of the roll (upper surface 6), so that the hardness in the vertical direction is greater.

[0026] In this way, the mattress body 3 is formed such that the upper surface 6 and the lower surface 7, which have a higher filament density and are harder than the middle portion 8, are formed into planes extending in the front-to-back and left-to-right directions, so that the harder portions of the upper surface 6 and the lower surface 7 continue longer in the front-to-back and left-to-right directions than in the up-to-down direction. As a result, the mattress body 3 is harder in the front-to-back and left-to-right directions, which are perpendicular to the compression direction, than in the up-to-down direction, which is the compression direction when compressed when manufacturing the compressed mattress 1 described below.

[0027] The compressed mattress 1 can be manufactured as described below.

[0028] First, as shown in Figure 3(a), the mattress body 3 is housed inside the cover 2 to form the mattress 5. The mattress 5 (cover 2 and mattress body 3) is in a state where it contains air inside (inflated state), just like when in use.

[0029] Next, as shown in Figure 3(b), a nonwoven fabric 9 that is slightly larger than the underside of the mattress 5 is laid directly below the mattress 5, and further, a flexible sheet 10 made of transparent vinyl or the like that is slightly larger than the underside of the mattress 5 and the nonwoven fabric 9 is laid directly below the nonwoven fabric 9. Further, a nonwoven fabric 11 that is slightly larger than the upper surface of the mattress 5 is laid directly above the mattress 5, and further, a flexible sheet 12 made of transparent vinyl or the like that is slightly larger than the upper surface of the mattress 5 and the nonwoven fabric 11 is laid directly above the nonwoven fabric 11.

[0030] Next, as shown in Figure 3(c), the mattress 5 is stretched in the front-to-back direction (left-to-right direction in Figure 3), which corresponds to the height direction of the person lying down, and the mattress 5 sandwiched between the upper and lower sheets 10, 12 and the nonwoven fabrics 9, 11 is compressed in the vertical direction by pressing from above, and the air inside the mattress 5 and between the mattress 5 and the upper and lower sheets 10, 12 and the nonwoven fabrics 9, 11 is forcibly expelled to the outside.

[0031] Next, as shown in Figure 3(d), the outer edges (peripheries) of the upper and lower sheets 10, 12 that protrude outward from the outer peripheries of the mattress 5 and the upper and lower nonwoven fabrics 9, 11 are sealed together by heat welding or the like. As a result, the storage bag 4 consisting of the upper and lower sheets 10, 12 is formed with the mattress 5 and the upper and lower nonwoven fabrics 9, 11 stored inside.

[0032] In addition, it is sufficient if the mattress body 3 is ultimately stored inside the cover 2 and then compressed and stored in a sealed state in the storage bag 4.For example, the mattress 5 and the upper and lower nonwoven fabrics 9, 11 may be stored in a flexible storage bag 4 with an opening and then compressed.

[0033] Next, as shown in Figure 3(e), the mattress 5 that has been compressed and stored in a sealed state in the storage bag 4 is rolled up into a roll. Here, the mattress 5 is rolled up from the end side along the longitudinal direction so that the upper surface of the mattress 5 and the upper surface 6 of the mattress main body 3 are always inside the lower surface of the mattress 5 and the lower surface 7 of the mattress main body 3 at the same position, thereby reducing the radius when rolled up.

[0034] In this manner, a compressed mattress 1 can be manufactured in which the mattress body 3 is stored inside the cover 2, compressed and stored in a sealed state in a storage bag 4, and wound into a roll, as shown in Figure 3(f).

[0035] By tearing the storage bag 4 and letting air into the compressed mattress 1, the mattress 5 (mattress body 3) can be restored to its expanded state and can be used immediately.

[0036] As described above, the compressed mattress 1 has a mattress body 3 made of a three-dimensional filament assembly in which filaments are woven in the front-to-back direction, which corresponds to the height of a person lying down, as well as the left-to-right direction and the up-to-down direction, and is configured to be harder in the front-to-back and left-to-right directions, which are perpendicular to the compression direction, than in the up-to-down direction, which corresponds to the compression direction.

[0037] Therefore, the compressed mattress 1 having the above configuration can be transported in a compressed state, thereby reducing the occupied area and reducing transportation costs, and moreover, by opening the storage bag 4, the mattress body 3 can be restored well to its pre-compression shape.

[0038] The compressed mattress 1 is configured such that the upper surface 6 and / or the lower surface 7 of the mattress body 3 is harder than the intermediate portion 8 between the upper surface 6 and the lower surface 7 .

[0039] Therefore, in the compressed mattress 1 having the above configuration, opening the storage bag 4 allows the mattress body 3 to be restored to its pre-compression shape more satisfactorily.

[0040] In addition, the compressed mattress 1 is configured such that the upper surface 6 or the lower surface 7 of the mattress body 3, which is on the outside when rolled up, is harder than the lower surface 7 or the upper surface 6 of the mattress body 3, which is on the inside.

[0041] Therefore, in the compressed mattress 1 having the above configuration, when the storage bag 4 is opened to restore the mattress body 3 to its pre-compression shape, the mattress body 3 spreads out flat and is prevented from forming a bending tendency in the mattress body 3. [Explanation of symbols]

[0042] 1 Compressed Mattress 2 Covers 3 Mattress body 4 Storage bag 5 Mattress 6 Top surface 7 Bottom surface 8 Middle part 9,11 Nonwoven fabric 10,12 Sheet

Claims

1. In a compressed mattress, the mattress body is stored inside the cover, compressed and stored in a sealed storage bag, and then wound into a roll. The mattress body is made of a three-dimensional filament bonded body in which filaments are knitted in the front-back direction, which corresponds to the height direction of a person lying down, the left-right direction and the up-down direction, and is characterized in that the front-back direction and the left-right direction, which are perpendicular to the compression direction, are harder than the up-down direction, which corresponds to the compression direction.

2. 2. The compressed mattress according to claim 1, wherein the upper surface and / or the lower surface of the mattress body is harder than the intermediate portion between the upper and lower surfaces.

3. A compressed mattress as described in claim 2, characterized in that the upper or lower surface of the mattress body that is on the outside when rolled up is harder than the lower or upper surface of the mattress body that is on the inside.

4. In a method for manufacturing a compressed mattress, a mattress body is housed inside a cover, compressed and stored in a sealed storage bag, and then wound into a roll, This method for manufacturing a compressed mattress is characterized by using a mattress body made of a three-dimensional filament bond in which filaments are woven in the front-to-back direction, which corresponds to the height direction of a person lying down, and the left-to-right direction and the up-to-down direction, and which is harder in the front-to-back and left-to-right directions perpendicular to the compression direction than in the up-to-down direction, which corresponds to the compression direction, and compressing the mattress body in the up-to-down direction and then winding it into a roll.

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