Laminate, mattress and sofa bed

Abstract

To provide a laminate that has excellent shape retainability and durability for a long term without compromising cushioning properties.SOLUTION: A laminate 1 comprises a first structure 2 and a second structure 3 which consist of three-dimensional net formed by heat sealing of spirally and randomly entangling continuous filaments containing thermoplastic resin. The first structure 2 and the second structure 3 are formed with different void ratios from each other and are laminated without adhesion. The first structure 2 has a bent part 2a with one side of a surface lying on the opposite side of the second structure 3 across a contact surface 4 being formed in an R-shape.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a laminate that has excellent shape retention and durability for a long period of time without impairing cushioning properties, a mattress that uses the laminate as a filling material, and a sofa bed that uses the mattress. [Background technology]

[0002] Conventionally, a three-dimensional mesh structure has been used as the filling material for mattresses. The structure is obtained by spirally and randomly entangling continuous filaments of thermoplastic resin extruded from a porous nozzle and then thermally fusing them together.

[0003] It is often difficult to provide mattresses using such fillings with the elasticity, appropriate resilience, breathability, lightness, and other properties that affect the comfort of sitting and sleeping using a single three-dimensional mesh structure, so mattresses made by stacking multiple three-dimensional mesh structures have been developed.

[0004] For example, a conventional mattress is made by laminating and bonding a first polyurethane foam and a second polyurethane foam having a harderness than the first polyurethane foam with an adhesive layer sandwiched between them, and a third polyurethane foam having a harderness than the second polyurethane foam and an air permeability of 70 l / min or more in accordance with ASTM D7574 is sandwiched between either the first polyurethane foam or the second polyurethane foam and the adhesive layer at both widthwise ends of the mattress.This prevents the mattress user or caregiver from becoming unstable when they sit or lean against both widthwise ends of the mattress, thereby supporting caregiving work, etc. (see Patent Document 1).

[0005] Furthermore, conventional cushion fillings are made by laminating soft urethane foam with open cells and / or interconnected spaces on one or both sides of a three-dimensional mesh structure formed by heat-fusing filaments, the raw material or main ingredient of which is polyethylene thermoplastic resin or polyester thermoplastic elastomer, which are spirally and disorderly entangled in a helical pattern, and this results in a cushion that is light, breathable, washable, and hygienic, while having a certain level of resilience and shape retention at an appropriate thickness (see Patent Document 2). [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent Publication No. 2021-108745 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-226230 Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the mattress disclosed in Patent Document 1, the first polyurethane foam and the second polyurethane foam are bonded together via an adhesive, and the cushioning properties of the mattress are impaired when the adhesive hardens. Furthermore, when this mattress is used on a sofa or the like, and the user leans back and relaxes with their legs stretched out, the user's weight (load) is applied not only in the vertical direction but also in the horizontal direction, which is perpendicular to the vertical direction. If the mattress's inner material is a laminate bonded with an adhesive as described in Patent Document 1, the first polyurethane foam and the second polyurethane foam are firmly bonded, so the bonded surface is subjected to a large load, and when the bond can no longer withstand the load, the bond may come apart, causing damage to the inner material.

[0008] Furthermore, the cushion filling disclosed in Patent Document 2 above describes that the first and second layers may be laminated without contact and that the loop sizes may be different. However, there is no disclosure of a specific configuration for preventing misalignment (slippage) between the first and second layers caused by the load applied when a user sits on the cushion filling, which is a problem particularly when the cushion filling is used on a sofa or the like.

[0009] The present invention has been made to solve the above-mentioned problems, and aims to provide a laminate that has excellent shape retention and durability for a long period of time without compromising cushioning properties, a mattress that uses the laminate as a filling material, and a sofa bed that uses the mattress. [Means for solving the problem]

[0010] The laminate of the present invention comprises a first structure and a second structure each having a three-dimensional mesh formed by helically and randomly entangling continuous filaments containing a thermoplastic resin and heat-fusing them together, the first structure and the second structure having different porosities from each other and laminated with their contact surfaces not bonded together, and the first structure has a curved portion on one side of the surface opposite the second structure across the contact surface, the curved portion having an R-shaped curve.

[0011] As described above, in the present invention, the laminate comprises the first structure and the second structure, which have different porosities and are laminated without bonding, and the first structure has a curved portion formed in an R-shape on one side of the surface opposite the second structure, so that the contact area between the first structure and the second structure does not harden due to solidification by an adhesive or the like, and cushioning properties are not impaired, compared to when the first structure and the second structure are bonded together. Furthermore, because these structures are formed by heat-sealing continuous filaments that are helically and randomly entangled, the unevenness formed on the contact surface differs between the first structure and the second structure, and an anchor effect suppresses slippage of the first structure, improving the shape retention of the laminate. Furthermore, since the porosity of the first structure and the second structure is different, the load applied to the laminate can be attenuated and dispersed, thereby improving the durability (service life) of the laminate. Furthermore, since the first structure has a curved portion formed in an R-shape, for example, when a user sits on a sofa using the laminate, the user can lower their feet from the sofa to the floor in a relaxed position, thereby achieving a relaxing effect.

[0012] In the laminate of the present invention, if necessary, the first structure has the curved portion and a main portion excluding the curved portion, and the porosity of the curved portion is formed to be smaller than the porosity of the main portion.

[0013] In this way, in the present invention, the porosity of the curved portion of the first structure is formed to be smaller than the porosity of the main portion, so that the strength of the curved portion is made greater than the strength of the main portion, thereby further improving the durability of the curved portion, which is the end portion of the first structure.

[0014] In the laminate according to the present invention, the second structure may have a curved portion, where one side of the surface opposite to the first structure is formed in an R-shape, as needed.

[0015] In this way, in the present invention, since the second structure has the curved portion formed in an R-shape extending over one side surface on the same side as the first structure, when the second structure is used as the lower tier, the load acting on the second structure can be distributed by the curved portion of the second structure, thereby improving the durability of the laminate.

[0016] In the laminate of the present invention, if necessary, the second structure has the curved portion and a main portion excluding the curved portion, the first structure is formed thinner than the second structure, and the porosity of the main portion of the first structure is formed greater than the porosity of the main portion of the second structure.

[0017] In this way, in the present invention, the first structure is formed thinner than the second structure, and the porosity of the main part of the first structure is formed greater than the porosity of the main part of the second structure. Therefore, the soft and thin first structure can be supported by the second structure, which is harder than the first structure. This ensures cushioning by the first structure, while the second structure attenuates the user's weight, thereby further improving the durability of the laminate.

[0018] In the laminate according to the present invention, the first structure and the second structure each have a slit formed on the contact surface so as to face each other, as necessary.

[0019] As described above, in the present invention, since the first structure and the second structure have slits formed so as to face each other on the contact surface, the first structure and the second structure are partitioned by the slits, and multiple regions with interrupted continuous lines can be formed. Each region partitioned by the slits is connected vertically, and each pair of upper and lower regions of the first structure and the second structure function like an independent spring, and a load applied within a predetermined range on the top surface of the first structure is absorbed within the region corresponding to the predetermined range, thereby improving the shape retention of the first structure and the second structure.

[0020] The mattress of the present invention comprises the laminate, an inner cover that houses the laminate, and an outer cover that houses the inner cover that houses the laminate, and the inner cover has cushioning material that is compartmentalized and housed from one side of the laminate where the curved portion of the first structure is formed to the surface.

[0021] In this way, in the present invention, the inner cover that houses the laminate has the cushioning material housed in a compartmented area, so the cushioning material does not shift from one compartment to another, and uniform cushioning can be achieved throughout the mattress. Furthermore, since the laminate is covered with the inner cover and the outer cover, slippage between the first structure and the second structure that constitute the laminate can be suppressed by the inner cover and the outer cover, thereby assisting in improving the shape retention of the laminate.

[0022] The sofa bed of the present invention is a sofa bed comprising: a main body portion which is hollow inside and has a seat portion for a user to sit on and a backrest portion which supports the user's back; a slide portion which can be stored within the cavity of the main body portion and can be pulled out from the front side of the main body portion; and a foldable mattress portion which is placed on the upper surface of the seat portion of the main body portion, or on the upper surface of the seat portion of the main body portion and the upper surface of the slide portion.By pulling out the slide portion from the cavity of the main body portion, the sofa bed can be transitioned from the sofa state to the bed state, and in the sofa state, the mattress portion comprises a seat mattress which is placed on the seat portion and a back mattress which is placed on the backrest portion, and at least the seat mattress is formed from the mattress.

[0023] In this way, the present invention comprises the main body portion, the slide portion, and the mattress portion, and the seat mattress in the mattress portion is formed from the mattress. Therefore, when a user sits on the seat mattress, the user can stretch (lower) their legs in a natural manner along the curved portion of the first structure that constitutes the laminate, and can enjoy a sense of relaxation.

[0024] In the sofa bed of the present invention, if necessary, the backrest portion has a plate-shaped member arranged on the user side, and the lower end of the plate-shaped member extends to the curved portion of the lower part of the back mattress when in the bed state.

[0025] In this way, in the present invention, the lower end of the plate-shaped member in the backrest portion extends to the curved portion of the lower part of the back mattress when in the bed state, so when the back mattress is pressed against the plate-shaped member of the backrest portion, the curved portion of the lower part of the back mattress can abut against the lower end of the plate-shaped member.When the sofa bed is transitioned from the bed state to the sofa state, the back mattress can be raised by sliding it against the plate-shaped member of the backrest portion by pushing the slide portion on which the seat mattress is placed into the cavity of the main body portion without folding the back mattress onto the seat mattress. [Brief explanation of the drawings]

[0026] [Figure 1] 1A and 1B are diagrams showing a schematic configuration of a laminate according to a first embodiment of the present invention, in which (a) is a plan view and (b) is a side view. [Figure 2] FIG. 3 is a schematic view showing another example of the laminate according to the first embodiment of the present invention. [Figure 3] FIG. 3 is a schematic view showing another example of the laminate according to the first embodiment of the present invention. [Figure 4] 1 is a schematic view of a laminate manufacturing apparatus according to a first embodiment of the present invention. [Figure 5] 1 is an enlarged view of a main part of a laminate manufacturing apparatus according to a first embodiment of the present invention. [Figure 6] FIG. 2 is a schematic diagram for explaining the function of the laminate according to the first embodiment of the present invention. [Figure 7] FIG. 2 is a schematic diagram for explaining the function of the laminate according to the first embodiment of the present invention. [Figure 8] 10A and 10B are diagrams showing a schematic configuration of a mattress according to a second embodiment of the present invention, in which (a) is a plan view and (b) is an enlarged cross-sectional view taken along line AA of (a). [Figure 9] FIG. 10 is a perspective view showing a schematic configuration of a sofa bed according to a third embodiment of the present invention. [Figure 10]FIG. 10 is a schematic cross-sectional view showing another example of the backrest portion of the sofa bed according to the third embodiment of the present invention. [Figure 11] FIG. 10 is a schematic cross-sectional view showing another example of the backrest portion of the sofa bed according to the third embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0027] (First embodiment of the present invention) A laminate according to a first embodiment of the present invention will be described below with reference to Figures 1 to 7. Throughout this embodiment, the same elements are denoted by the same reference numerals.

[0028] The laminate 1 according to this embodiment is constructed by laminating, without bonding, first structures 2 and second structures 3, which are three-dimensional net-like structures formed by thermally fusing wires containing a thermoplastic resin that are disorderly entangled in a spiral shape. The laminate 1 has a substantially rectangular parallelepiped shape, and at least one side is formed in an R-shape.

[0029] The first structure 2 has a substantially rectangular parallelepiped shape, and at least one side is rounded to form a curved portion 2a. This curved portion 2a is one side on the surface opposite to the surface in contact with the second structure 3. Note that the shape of the first structure 2 is not limited to a substantially rectangular parallelepiped shape, and the shape can be changed as appropriate depending on the application.

[0030] The curved portions 2a are formed to have a larger porosity than the main portion 2b of the first structure 2 excluding the curved portions 2a. Here, the porosity refers to the ratio of the volume of the filaments to a predetermined space. The porosities of the curved portions 2a and the main portion 2b can be set appropriately depending on the required strength. The thickness of the curved portion 2a from the surface can be set appropriately depending on the required strength, but is set to, for example, 5 cm from the surface. As described above, in the first structure 2, the porosity of the curved portion 2a is formed to be smaller than the porosity of the main portion 2b, so that the strength of the curved portion 2a is made greater than the strength of the main portion 2b, thereby further improving the durability of the curved portion 2a, which is the end portion of the first structure 2.

[0031] The second structure 3 is stacked together with the first structure 2 via the contact surface 4 . The second structure 3 has a substantially rectangular parallelepiped shape, and at least one side is rounded to form a curved portion 3a. This curved portion 3a is one side on the surface opposite to the surface in contact with the first structure 2, and is formed on the same surface of the laminate 1 as the curved portion 2a of the first structure 2 so as to face each other. In this embodiment, it is sufficient that at least the first structure 2 has a curved portion 2a formed therein, and the second structure 3 may or may not have a curved portion 3a.

[0032] As described above, since the second structure 3 has a curved portion 3a formed in an R-shape on one side surface on the same side as the first structure 2, when the second structure 3 is used as the lower layer, the load on the second structure 3 can be distributed by the curved portion 3a of the second structure 3, thereby improving the durability of the laminate 1. That is, when a load is applied to the laminated body 1 due to a user sitting on it, there is a risk of damage to one side of the second structure 3 that comes into contact with the ground. In particular, when the laminated body 1 is used on a sofa or the like, there are areas that are more susceptible to load than other areas, such as the side where the user stretches their legs. On the other hand, when a user lifts the laminated body 1, the user grasps the lower side of the second structure 3 to lift the laminated body 1. In response to these problems, the second structure 3 has a curved side that corresponds to one side of the laminated body 1, which distributes the load described above and improves the durability of the second structure 3.

[0033] The curved portions 3a are formed to have a larger porosity than the main portion 3b excluding the curved portions 3a in the second structure 3. The porosity of the curved portions 3a and the main portion 3b can be set appropriately depending on the required strength. The thickness of the curved portion 3a from the surface can be set appropriately depending on the required strength, but is set to, for example, 5 cm from the surface.

[0034] The thickness of the first structure 2 is formed to be thinner than the thickness of the second structure 3 in the stacking direction of the laminate 1. The thicknesses of the first structure 2 and the second structure 3 are not particularly limited, but for example, the thickness of the first structure 2 can be set within a range of 40 to 50 mm, and the thickness of the second structure 3 can be set within a range of 100 to 110 mm.

[0035] Furthermore, the porosity of the main portion 2b of the first structure 2 is formed to be different from the porosity of the main portion 3b of the second structure 3. For example, the porosity of the main portion 2b of the first structure 2 can be made smaller than the porosity of the main portion 3b of the second structure 3.

[0036] As described above, the first structure 2 is formed thinner than the second structure 3, and the porosity of the main part 2b of the first structure 2 is formed to be greater than the porosity of the main part 3b of the second structure 3. Therefore, the soft and thin first structure 2 can be supported by the second structure 3, which is harder than the first structure 2. This ensures cushioning properties through the first structure 2, while the second structure 3 attenuates the user's weight, thereby further improving the durability of the laminate 1.

[0037] Furthermore, the curvature of the curved portion 2a in the first structure 2 and the curvature of the curved portion 3a in the second structure 3 can be set appropriately, and for example, they can be the same curvature or different curvatures from each other.

[0038] As shown in FIG. 2, the first structure 2 and / or the second structure 3 may each have a slit formed therein. As shown in Fig. 2(b), the first structure 2 has slits 2c and 2d arranged in a grid pattern on the contact surface 4 side with the second structure 3. The slits 2c are linear, and a plurality of slits 2c are formed between the side surface 2e and the side surface 2f that face each other in the longitudinal direction of the first structure 2. The slits 2d are linear, and a plurality of slits 2d are formed between the side surface 2g that faces each other in the lateral direction of the first structure 2 and the curved portion 2a. Here, the slits 2d may be formed up to the curved portion 2a. Similarly, as shown in Fig. 2(c), the second structure 3 has slits 3c and 3d formed on the contact surface side with the first structure 2 and arranged in a grid pattern. The slits 3c are linear, and a plurality of slits 3c are formed between the side surface 3e and the side surface 3f that face each other in the longitudinal direction of the second structure 3. The slits 3d are linear, and a plurality of slits 3d are formed between the side surface 3g that faces each other in the lateral direction of the second structure 3 and the curved portion 3a. Here, the slits 3d may be formed up to the curved portion 3a. The slits 2c and 2d of the first structure 2 and the slits 3c and 3d of the second structure 3 are arranged at the same position so as to face each other on the contact surface 4. That is, one region defined by the slits 2c and 2d of the first structure 2 is arranged so as to face each other on the contact surface 4 with one region defined by the slits 3c and 3d of the second structure 3.

[0039] In this way, since the first structure 2 and the second structure 3 have slits 2c, 2d and slits 3c, 3d formed opposite each other on the contact surface 4, the first structure 2 and the second structure 3 are partitioned by the slits 2c, 2d and slits 3c, 3d, and multiple regions with interrupted continuous lines can be formed. Each region partitioned by the slits 2c, 2d and slits 3c, 3d is connected vertically, and each pair of upper and lower regions of the first structure 2 and the second structure 3 functions like an independent spring, so that a load applied to a predetermined range on the top surface of the first structure 2 is received within the region corresponding to the predetermined range, thereby improving the shape retention of the first structure 2 and the second structure 3.

[0040] The shapes of the slits 2c, 2d of the first structure 2 and the slits 3c, 3d of the second structure 3 are not limited to linear shapes, and may be curved shapes such as wave shapes. Furthermore, the slit arrangement in the first structure 2 and the second structure 3 does not need to be in a lattice pattern, and for example, only the slit 2c may be formed in the first structure 2, and only the slit 3c may be formed in the second structure 3.

[0041] Furthermore, the slits in the first structure 2 and the second structure 3 may be arranged so that the slits 3c and 3d of the second structure 3 partially overlap with the slits 2c and 2d of the first structure 2. For example, as shown in Fig. 3, the slits 3c and 3d of the second structure 3 may be formed at an angle with respect to the slits 2c and 2d so as to pass through each lattice point formed by the slits 2c and 2d of the first structure 2. In this case, four regions defined by the slits 3c and 3d of the second structure 3 are arranged on the contact surface 4 so as to face one region defined by the slits 2c and 2d of the first structure 2. As a result, when the load acting on the upper surface of the first structure 2 is transmitted to the second structure 3, the pressure is received within a specific area of ​​the second structure 3 surrounded by the slits 3c and 3d and can be dispersed within this specific area, thereby improving durability as well as shape retention.

[0042] The thermoplastic resin used to form the filaments that make up the first structure 2 and the second structure 3 can be any conventionally known thermoplastic resin used as a mattress filling material, including, for example, polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides such as nylon 66, polyvinyl chloride, polystyrene, copolymers and elastomers copolymerized based on the above resins, blends of the above resins, etc. The thermoplastic resin used for the first structure 2 and the second structure 3 can be the same resin, or different resins can be used.

[0043] Next, an example of a manufacturing apparatus and a manufacturing method for the first structure 2 and the second structure 3 will be described with reference to FIGS.

[0044] The first structure 2 and the second structure 3 are fabricated by a manufacturing apparatus 100 shown in FIG. The manufacturing apparatus 100 includes an extrusion molding section 110 that melts thermoplastic resin and discharges it vertically downward, and a structure forming section 120 that randomly entangles the discharged thermoplastic resin in a spiral shape to form a three-dimensional mesh structure.

[0045] The extrusion molding section 110 includes a hopper 111 into which thermoplastic resin raw material is fed, a melting section 112 that heats and pressurizes the raw material fed into the hopper 111 to melt it, and a discharge section 114 that discharges the molten raw material from a nozzle 115.

[0046] A rotatable screw 113 is housed within melting section 112, which conveys the raw material supplied from hopper 111 to discharge section 114. The temperature within melting section 112 is set to, for example, a range of 100 to 400°C, and the pressure is set to, for example, a range of 0.2 to 25 MPa.

[0047] A detachably fixed nozzle 115 is provided at the lower end of the discharge section 114, and openings are formed in the bottom surface of the nozzle 115 for discharging the molten raw material toward the structure forming section 120. These openings are, for example, arranged in a staggered pattern at equal intervals, but are not limited to this. The thickness and porosity of the first structure 2 and the second structure 3 can be changed by adjusting the number of openings in the nozzle 115, their arrangement intervals, and their arrangement range.

[0048] Structure forming section 120 includes a water tank 121 for cooling and solidifying the molten raw material, a pair of front and rear endless conveyors 122 submerged in water tank 121, and transport rollers 123a to 123d for transporting the structure formed by cooling and solidifying out of water tank 121. In addition, a regulating plate 124 is disposed between water tank 121 and the structure forming section 120, which is detachable from water tank 121 and adjusts the three-dimensional net-like structure into a predetermined shape.

[0049] Restriction plate 124 has fixed surface 124a that is detachably fixed to water tank 121, and curved concave surface 124b that is continuous with fixed surface 124a and extends toward the molten raw material discharged from discharge section 114. Restriction plate 124 is disposed such that at least curved concave surface 124b is inclined toward the discharged molten raw material side with respect to the horizontal plane.

[0050] The first structure 2 and the second structure 3 are fabricated using the above-mentioned manufacturing apparatus 100 as follows.

[0051] First, a thermoplastic resin raw material is charged into a hopper 111. The charged raw material is supplied to an extrusion molding section 110, and is extruded into a discharge section 114 by a screw 113 while being heated and melted in a melting section 112 of the extrusion molding section 110.

[0052] The molten raw material extruded into the discharge section 114 is discharged in a linear form from the opening of the nozzle 115 and sent to the structure forming section 120 by gravity descent. At this time, the wires that descend to the area where the regulating plate 124 is arranged are not directly thrown into the water tank 121, but travel along the curved concave surface 124b of the regulating plate 124 and are thrown into the water tank 121 together with the wires that descend near the curved concave surface 124b (see Figure 5).

[0053] The raw material that has been dropped directly into the water tank 121 from the discharge section 114 and the raw material that has been dropped into the water tank 121 along the regulating plate 124 are fed between a pair of endless conveyors 122 . The filaments introduced into the water tank 121 are shaped by a pair of endless conveyors 122, and then buoyant forces cause them to spirally and randomly entangle to form a three-dimensional net-like structure. This structure is cooled and solidified in the water tank 121 while being guided by the conveying rollers 123a to 123d, and then carried out of the water tank 121.

[0054] The structure carried out of the water tank 121 has moisture removed by compressed air and is cut to a predetermined size, thereby producing the first structure 2 and the second structure 3.

[0055] Next, the function of the laminate 1 according to this embodiment will be described with reference to FIGS. The following describes the case where a mattress using the laminate 1 as a filling material is used in a sofa. The mattress is used with the first structure 2 as the upper layer and the second structure 3 as the lower layer, with the curved portion 2a of the first structure 2 and the curved portion 3a of the second structure 3 positioned at the front of the sofa.

[0056] When a user sits on the mattress in the above-described state, a load F1 from the user is applied downward in the stacking direction to the laminated body 1. In addition, a load F2 is applied to the curved portion 2a of the first structure 2 in the laminated body 1 that holds the wearer's feet, in a direction from the curved portion 2a toward the main portion 2b.

[0057] Here, if the porosity of the first structure 2 is greater than the porosity of the second structure 3 (see Figure 6), the cushioning properties of the first structure 2 are maintained, while the load F1 transmitted from the first structure 2 to the second structure 3 is attenuated (load F1') by the second structure 3, which is formed to be harder, and the load F1 can be sufficiently supported.

[0058] On the other hand, when the porosity of the second structure 3 is greater than the porosity of the first structure 2 (see FIG. 7), the cushioning properties are reduced, but the change in shape of the first structure 2 due to the load F1 is small, and therefore the second structure 3 is able to support the load F1 applied to the first structure 2 by distributing it across the entire contact surface with the first structure 2 (load F1″), thereby preventing deformation of the second structure 3 and improving durability.

[0059] Furthermore, the load F2 causes the first structure 2 to slip backward relative to the second structure 3. In the laminate 1, the first structure 2 and the second structure 3 are formed with different porosities, and therefore the size and number of projections and depressions formed on the contact surface 4 between the first structure 2 and the second structure 3 are different. As a result, an anchor effect acts between the first structure 2 and the second structure 3, making it possible to suppress slippage of the first structure 2 due to the load F2, and improving the shape retention of the laminate 1.

[0060] In this way, the laminate 1 includes the first structure 2 and the second structure 3, which have different porosities and are laminated without bonding, and the first structure 2 has a curved portion 2a formed in an R-shape on one side of the surface opposite the second structure 3. Therefore, compared to when the first structure 2 and the second structure 3 are bonded, the contact portion between the first structure 2 and the second structure 3 does not harden due to solidification by an adhesive or the like, and cushioning properties are not impaired. Furthermore, because these structures 2 and 3 are formed by heat-sealing continuous filaments that are helically and randomly entangled, the unevenness formed on the contact surface 4 differs between the first structure 2 and the second structure 3, and the anchor effect suppresses slippage of the first structure 2, thereby improving the shape retention of the laminate 1.

[0061] Furthermore, since the porosity of the first structure 2 and the second structure 3 is different, the load applied to the laminate 1 can be attenuated and dispersed, thereby improving the durability (service life) of the laminate 1.

[0062] Furthermore, since the first structure 2 has a curved portion 2a formed in an R-shape, for example, when a user sits on a sofa using the laminated body 1, the user can lower their feet from the sofa to the floor in a relaxed posture, thereby achieving a relaxing effect.

[0063] (Second embodiment of the present invention) The mattress according to this embodiment uses the laminate according to the first embodiment as a filling material, and will be described below with reference to FIG. In the following description, the description of the configuration that overlaps with the first embodiment will be omitted.

[0064] The mattress 10 according to this embodiment includes a laminate 1, an inner cover 11 that houses the laminate 1, and an outer cover 12 that houses the laminate 1 housed in the inner cover 11.

[0065] The inner cover 11 is formed so that the laminate 1 can be freely removed. The inner cover 11 has a fabric material 11a and cushioning materials 11b that are contained within the fabric material 11a and are partitioned by sewing lines 11c. More specifically, the front and back surfaces of the inner cover 11 are sewn in a grid pattern, and the inner cover 11 is partitioned into multiple regions by the sewing lines 11c, with cushioning materials 11b contained in each region. For example, a washable and breathable material can be used as the fabric material 11a of the inner cover 11. For example, polyester cotton can be used as the cushion material 11b.

[0066] The outer cover 12 is formed so that the inner cover 11 that houses the laminate 1 can be freely removed. The outer cover 12 is formed, for example, from a washable, breathable fabric material.

[0067] The inner cover 11 and the outer cover 12 are provided with fasteners on their side surfaces, allowing the inner cover 11 and the outer cover 12 to be opened and closed. The fasteners are preferably provided on the side opposite to the surface used by the user.

[0068] In this way, since the inner cover 11 that houses the laminate 1 has cushioning material 11b housed in a compartmented area, the cushioning material 11b does not shift from one compartmentalized area to another, and uniform cushioning properties can be achieved throughout the mattress 10.

[0069] Furthermore, if the porosity of the first structure 2 is formed to be smaller than the porosity of the second structure 3, the flexibility will gradually decrease from the cushion material 11b to the second structure 3, and the cushioning properties can be changed in three stages to ensure more comfortable cushioning, and the load on the mattress 10 can be gradually distributed in three stages from the cushion material 11b to the second structure 3, further improving the durability of the mattress 10.

[0070] Furthermore, since the laminate 1 is covered with the inner cover 11 and the outer cover 12, the inner cover 11 and the outer cover 12 can suppress slippage between the first structure 2 and the second structure 3 that constitute the laminate 1, thereby additionally improving the shape retention of the laminate 1.

[0071] (Third embodiment of the present invention) The sofa bed according to this embodiment uses a mattress that uses the laminate according to the first embodiment as a filling material, and will be described below with reference to Figs. 9 to 11. In the following description, the description of the configurations that overlap with the above-described embodiments will be omitted.

[0072] The sofa bed 20 is configured to include a main body portion 30 having a hollow interior, a slide portion 40 that can be stored in the hollow of the main body portion 30 and can be pulled out from the front side of the main body portion 30, and a foldable mattress portion 50 that is placed on the top surface of the main body portion 30 or on the top surfaces of the main body portion 30 and the slide portion 40.

[0073] The main body 30 is composed of a backrest 31, a seat 32 disposed in front of the backrest 31, and a pair of side plates 33 that sandwich the backrest 31 and seat 32 from the left and right. The backrest 31, seat 32, and side plates 33 are integrally formed with fasteners such as bolts and are formed to be disassembled.

[0074] The backrest portion 31 is configured by connecting two plate-like members 31a and 31b of different widths with a support member 31c having a triangular cross section sandwiched therebetween.

[0075] The plate-like member 31a disposed on the user side is made of a rectangular flat plate and is formed so as to be inclined with respect to the vertical direction of the installation surface of the sofa bed 20.

[0076] Plate-shaped member 31b is made of a rectangular flat plate and is erected in a generally vertical direction relative to the installation surface of sofa bed 20. Plate-shaped member 31a and plate-shaped member 31b are arranged in a gable roof shape, with the upper end of plate-shaped member 31b located near the upper end of plate-shaped member 31a and facing plate-shaped member 31a across support member 31c. Plate-shaped member 31b is formed to be longer in the vertical direction than plate-shaped member 31a, and seat portion 32 is connected to this portion that is longer than plate-shaped member 31a with fasteners.

[0077] 10, the lower end of the plate-like member 31a preferably extends to the curved portion below the back mattress 52 in the mattress section 50 (the curved portion 3a of the second structure 3 arranged in the lower tier). In other words, when the plate-like member 31a and the back mattress 52 come into contact with each other, the contact point is preferably the curved portion 3a of the second structure 3 in the back mattress 52. In this way, since the lower end of the plate-shaped member 31a of the backrest portion 31 extends to the curved portion at the bottom of the back mattress 52 when in bed state, when the back mattress 52 is pressed against the plate-shaped member 31a of the backrest portion 31, the curved portion at the bottom of the back mattress 52 can abut against the lower end of the plate-shaped member 31a.When transitioning the sofa bed 20 from the bed state to the sofa state, the back mattress 52 can be raised by sliding it against the plate-shaped member 31a of the backrest portion 31 by pushing the slide portion 40 on which the seat mattress 51 is placed into the cavity of the main body portion 30 without folding the back mattress 52 onto the seat mattress 51.

[0078] 11, a curved portion 31d that curves toward the front side of the sofa bed 20 may be formed at the bottom of the plate-like member 31a. In this case, it is preferable that the curvature of the curved portion 31d and the curvature of the curved portion 3a of the second structure 3 that can abut against this curved portion 31d in the bed state are the same, from the viewpoint of making it easier to raise the back mattress 52 toward the backrest portion 31.

[0079] The seat 32 has a frame 32a made of a top panel, connecting members 32b that reinforce the strength of the frame 32a, multiple floorboards 32c arranged at equal intervals in a comb-like pattern on the frame 32a and connecting members 32b, and legs 32d that are fixed via corner posts and crossbeams. The floorboards 32c are arranged parallel to each other in the front-to-rear direction of the sofa bed 20. The seat portion 32 is fixed to the lower portion of the backrest portion 31 by a fastener.

[0080] The sliding section 40 comprises a front panel 41 extending in the left-right direction, side panels 42 attached to both ends of the front panel 41, a plurality of sliding floor panels 43 fixed to the front panel 41 and arranged at equal intervals in a comb-like pattern along the front-to-rear direction, a support plate 44 arranged on the plurality of sliding floor panels 43 and supporting the sliding floor panels 43, and a plurality of front legs 45 attached to the sliding floor panels 43 at predetermined intervals.

[0081] The floor plates 32c of the seat 32 and the sliding floor plates 43 of the sliding portion 40 are arranged alternately. In other words, when the sliding portion 40 is moved horizontally into the cavity of the seat 32 and inserted, the sliding floor plates 43 are fitted between the floor plates 32c, and the floor plates 32c are fitted between the sliding floor plates 43, so that the seat 32 and the sliding portion 40 fit together, allowing the sliding portion 40 to be stored in the cavity of the seat 32.

[0082] The mattress section 50 comprises a seat mattress 51 disposed on the seat section and a back mattress 52 disposed on the backrest section 31 in a state where the slide section 40 is housed in the cavity of the seat section 32. The seat mattress 51 and the back mattress 52 are formed in a roughly rectangular parallelepiped shape, and when they are arranged side by side, one of the opposing sides is connected by a connecting part 53, so that they can be folded to either side.

[0083] The mattress 10 described in the first and second embodiments is used as the seat mattress 51 and the back mattress 52, but it may be used for at least one of them. For example, the laminate 1 having the curved portions 2a and 3a may be used as the inner material of the seat mattress 51, and a three-dimensional mesh structure having the curved portion 2a but not the curved portion 3a may be used as the inner material of the back mattress 52.

[0084] In the seat mattress 51, the laminate 1, which is the inner material, is housed with the first structure 2 as the upper stage and the second structure 3 as the lower stage facing the seat portion 32, with the curved portions 2a and 3a facing the opposite side of the back mattress 52. These curved portions 2a and 3a are positioned in front of the seat portion 32 when in sofa state.

[0085] In the back mattress 52, the laminated body 1, which is the inner material, is housed with the first structure 2 as the upper stage and the second structure 3 as the lower stage on the backrest 31 side, with the curved portions 2a and 3a facing away from the seat mattress 51. These curved portions 2a and 3a are positioned above the backrest 31 when in sofa state.

[0086] In this way, in the seat mattress 51 and the back mattress 52, the curved portion 2a of the first structure 2 and the curved portion 3a of the second structure 3 are arranged so as to face each other across the connecting portion 53, so that when the seat mattress 51 and the back mattress 52 are spread out horizontally, no depression is created in the central part of the mattress portion 50, and no discomfort is felt when the mattress portion 50 is spread out and used.

[0087] Next, how to use the sofa bed 20 will be described.

[0088] When the sofa bed 20 is changed from the sofa state to the bed state, the user first grasps the front panel 41 of the slide part 40 and pulls the slide part 40 forward. At this time, the seat mattress 51 is also pulled forward together with the slide part 40, and as the seat mattress 51 moves forward, the back mattress 52 is also pulled forward while sliding on the backrest part 31.

[0089] When the slide portion 40 is completely pulled out from the cavity of the seat portion 32, the back mattress 52 is placed on the floor board 32c of the seat portion 32, and the sofa bed 20 is placed in a bed state.

[0090] Next, when changing from the bed state to the sofa state, the back mattress 52 on the seat part 32 is folded onto the seat mattress 51, and then the slide part 40 is pushed into the cavity of the seat part 32 to store it, and finally the back mattress 52 is raised and leaned against the backrest part 31 to change into the sofa state. Here, the floor board 32c arranged on the frame portion 32a of the seat portion 32 is arranged on the same plane as the sliding floor board 43 of the sliding portion 40, so when the sliding portion 40 is stored in the seat portion 32, the mattress portion 50 does not get caught on the constituent members of the seat portion 32 and does not interfere with the storage of the sliding portion 40.

[0091] Note that, in order to prevent the sliding portion 40 from being pulled out excessively forward, a limiting member or the like may be provided on the sliding portion 40. For example, a limiting member protruding downward may be provided on one of the rear plates (on the backrest 31 side) of the sliding floor board 43, and when the sliding portion 40 is pulled out a predetermined amount, this limiting member is restricted by the front board 41 of the seat 32, preventing the sliding portion 40 from being pulled out further forward.

[0092] In this way, since the mattress is provided with a main body portion 30, a slide portion 40, and a mattress portion 50, and the seat mattress 51 in the mattress portion 50 is formed from the mattress 10, when the user sits on the seat mattress 51, the user can stretch (lower) their legs in a natural manner along the curved portion 2a of the first structure 2 that constitutes the laminated body 1, and can enjoy a sense of relaxation. Similarly, when the back mattress 52 is formed from the mattress 10, the user's head and neck (posterior cervical region) can be leaned along the curved portion 2a of the first structure 2 that constitutes the laminate 1 of the back mattress 52, allowing the user to feel even more relaxed.

[0093] Furthermore, in the first structure 2 in the seat mattress 51 and the back mattress 52, if the porosity of the curved portion 2a is formed to be smaller than the porosity of the main portion 2b, the strength of the curved portion 2a will be made greater than the strength of the main portion 2b, thereby maintaining strength against the load applied by the user's feet, head, etc. leaning on it, improving durability, and ensuring cushioning in the main portion 2b.

[0094] Furthermore, if the second structure 3 of the seat mattress 51 has a curved portion 3a and the porosity of the curved portion 3a is formed to be smaller than the porosity of the main portion 3b, the strength of the curved portion 3a will be greater than the strength of the main portion 3b, and when transitioning from the bed state to the sofa state, the strength against the load applied by the user's lifting action of the mattress portion 50 can be maintained, improving durability while ensuring cushioning in the main portion 3b. [Explanation of symbols]

[0095] 1. Laminate 2. First structure 2a Curved section 2b Main part 2c,2d slits 3 Second structure 3a Curved section 3b Main part 3c,3d slit 4 Contact surface 10 Mattress 11 Inner cover 11a Cloth material 11b Cushioning material 11c Sewing line 12 Outer cover 20 sofa bed 30 Main body 31 Backrest 32 Seat area 32a Frame 32b Joint 32c floorboard 32d legs 33 Side panel 40 Slide section 41 Front panel 42 Horizontal board 43 Sliding floorboard 44 Support plate 45 Front legs 50 Mattress section 51 Seat Mattress 52 Back Mattress 53 Connecting part 100 Manufacturing equipment 110 Extrusion molding section 111 Hopper 112 Welding section 113 Screw 114 Discharge section 115 nozzles 120 Structure forming part 121 Aquarium 122 endless conveyor 123a to 123d Conveyor rollers 124 Restriction Board 124a Fixed surface 124b curved concave surface

Claims

1. The thermoplastic resin-containing first structure and second structure are formed into a three-dimensional net shape by helically and randomly entangling continuous filaments containing a thermoplastic resin and heat-sealing the filaments, the first structure and the second structure are formed with different porosities and are laminated with their contact surfaces not bonded together; The first structure has a curved portion formed in an R-shape on one side of a surface opposite to the second structure across the contact surface. A laminate comprising:

2. The laminate according to claim 1 , The first structure has the curved portion and a main portion excluding the curved portion, and the porosity of the curved portion is formed to be smaller than the porosity of the main portion. A laminate comprising:

3. The laminate according to claim 2, The second structure has a curved portion formed in an R-shape on one side of a surface opposite to the first structure across the contact surface. A laminate comprising:

4. The laminate according to claim 3, the second structure has the curved portion and a main portion excluding the curved portion, the first structure is formed thinner than the second structure, The porosity of the main portion of the first structure is formed to be larger than the porosity of the main portion of the second structure. A laminate comprising:

5. The laminate according to claim 1 , The first structure and the second structure each have a slit formed on the contact surface so as to face each other. A laminate comprising:

6. The laminate according to any one of claims 1 to 5, an inner cover that houses the laminate; an outer cover that houses an inner cover that houses the laminate, The inner cover has cushioning material accommodated in a compartment from one side surface of the laminate where the curved portion of the first structure is formed to the surface. A mattress that features.

7. a main body portion having a hollow interior and including a seat portion for a user to sit on and a backrest portion for supporting the user's back; a slide portion that can be housed in the cavity of the main body portion and can be drawn out from the front side of the main body portion; A sofa bed comprising a foldable mattress portion placed on the upper surface of the seat portion of the main body portion, or on the upper surface of the seat portion of the main body portion and the upper surface of the slide portion, The sofa state can be changed into a bed state by pulling out the slide portion from the cavity of the main body portion, The mattress section includes a seat mattress disposed on the seat section and a back mattress disposed on the backrest section when the sofa is in the sofa state, and at least the seat mattress is formed of the mattress according to claim 6. A distinctive sofa bed.

8. The sofa bed according to claim 7, The backrest portion has a plate-like member disposed on the user side, and the lower end of the plate-like member extends to the curved portion of the lower part of the back mattress in the bed state. A distinctive sofa bed.

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