Manufacturing methods for bedding

Abstract

The present invention provides a body surface shape measuring device capable of measuring the body surface shape, including bone shape, that matches the actual sleeping posture of a human body when the muscles are relaxed, as well as bedding, a method for manufacturing bedding, a computer program, a pillow, and a method for manufacturing a pillow. [Solution] The bedding comprises a bedding body, a plurality of recesses and protrusions provided on the bedding body based on the shape of the body surface in a suspended state when the person is sleeping, and a plurality of contact parts that fit into the plurality of recesses and come into contact with the part of the person's body that bears the weight when they are sleeping.

Description

Technical Field

[0001] The present invention relates to a body surface shape measuring device, bedding, a method for manufacturing bedding, a computer program, a pillow, and a method for manufacturing a pillow.

Background Art

[0002] According to the results of the National Health and Nutrition Survey in 2016, the proportion of people who have not had sufficient rest through sleep in the most recent one-month period is 19.7%, and this proportion has been increasing year by year. According to the "Sleep Guidelines 2014 for Health Promotion" by the Ministry of Health, Labour and Welfare, it has been confirmed that when there are problems with sleep, anxiety and stress hormones increase, and accidents are likely to occur or depression is likely to develop. It has been shown that short sleep duration and insomnia cause problems such as obesity, hypertension, impaired glucose tolerance, circulatory diseases, and metabolic syndrome. To improve such various problems related to sleep, consumers are considering replacing their bedding. According to a certain questionnaire survey, "paying attention to sound sleep" and "pillow" are ranked first among goods.

[0003] Conventionally, various pillows have been developed to meet the demand for sound sleep. Conventional pillows include those with some material placed on the surface to make it soft or with a member for height adjustment placed inside (for example, Patent Document 1, etc.).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] It should be noted that the content in the original text about the "National Health and Nutrition Survey in 2016" was corrected to 2016 in the translation as the original text might have an incorrect reference. Also, the translation of some technical terms and expressions is based on common patent translation practices. If there are specific requirements for certain terms, further adjustments may be needed.When a pillow is made of soft urethane, or a urethane-gel pillow with gel attached to it, the distribution of head pressure varies among users. Some people may find it too soft, while others may find it too high. The same applies when height adjustment components are used. The same applies to pipe pillows; even if the height is controlled by the amount of pipe, they easily deform over time, and the height quickly becomes unsuitable, requiring repeated visits to the store for adjustment. While there are services that offer unlimited adjustments, it is inconvenient for consumers to have to go to the store multiple times, and this can lead to them purchasing other products as well.

[0006] This invention has been made in view of the above circumstances, and aims to provide a body surface shape measuring device, bedding, a method for manufacturing bedding, a computer program, a pillow, and a method for manufacturing a pillow, which can measure the body surface shape, including the bone shape, that matches the actual sleeping posture of a human body when the muscles are relaxed. [Means for solving the problem]

[0007] One aspect of the present invention relates to bedding comprising a bedding body, a plurality of recesses and protrusions provided on the bedding body based on the shape of the body surface of a person in a suspended sleeping position, and a plurality of contact parts that fit into the plurality of recesses and make contact with the part of the person's body that bears the weight of the person in a sleeping position. [Effects of the Invention]

[0008] According to the present invention, a mold is used to create recesses based on the body surface shape, including the bone shape, that match the actual sleeping posture of a relaxed human body. Contact parts formed based on the body surface shape and made contact with the areas where weight is applied are fitted into these recesses. Convex parts are provided on the bedding body corresponding to the recessed parts of the body surface shape. The body's contours, including the areas where weight is applied, are in close contact with the bedding, body pressure is well distributed, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also possible and requires fewer turns, resulting in good sleep. [Brief explanation of the drawing]

[0009] [Figure 1] It is a plan view of the pillow body and the contact part. [Figure 2] It is a perspective view of the body and the contact part. [Figure 3] It is an explanatory view for explaining a method of manufacturing the contact part. [Figure 4] It is a plan view showing a state where the body is housed in the inner cover. [Figure 5] It is a rear view showing a state where the body is housed in the inner cover. [Figure 6] It is a plan view of the pillow showing a state where the inner cover is housed in the outer cover. [Figure 7] It is a rear view of the pillow showing a state where the inner cover is housed in the outer cover. [Figure 8] It is a sectional view taken along line VIII-VIII of FIG. 6. [Figure 9] It is a sectional view taken along line IX-IX of FIG. 6. [Figure 10] It is a plan view showing the pipe housing part [Figure 11] It is a plan view showing the plate part. [Figure 12] It is a plan view of the pillow body and the contact part according to Embodiment 2. [Figure 13] It is a perspective view of the contact part. [Figure 14] It is a block diagram showing a bedding manufacturing system according to Embodiment 4. [Figure 15] It is a perspective view showing a body surface shape measuring device. [Figure 16] It is a schematic view showing a state of acquiring the body surface shape of a user in a sleeping posture using the body surface shape measuring device. [Figure 17] It is a perspective view showing a body surface shape measuring device according to Embodiment 5. [Figure 18] It is a schematic view showing a state of acquiring the body surface shape of a user in a sleeping posture using the body surface shape measuring device. [Figure 19] It is a plan view showing a mat manufactured using the body surface shape measuring device of the present embodiment. [Figure 20] It is a partial cross-sectional view of the mat. [Figure 21]It is a cross-sectional view showing the hip portion of the mat of Modification 1. [Figure 22] It is a block diagram showing a bedding manufacturing system according to Embodiment 5. [Figure 23] It is a flowchart showing the procedure of the manufacturing process of the mat by the control unit of the PC. [Figure 24] It is a perspective view showing the mat of Modification 2. [Figure 25] It is a perspective view showing the measurement unit of the body surface shape measuring device of Modification 3. [Figure 26] It is a plan view showing the body surface shape measuring device of Modification 4. [Figure 27] It is a cross-sectional view showing the body surface shape measuring device according to Embodiment 6. [Figure 28] It is a schematic diagram showing an example of a learning model. [Figure 29] It is a cross-sectional view showing the body surface shape measuring device according to Embodiment 8. [Figure 30] It is a plan view showing the pattern-taking material after pattern-taking. [Figure 31] It is a cross-sectional view showing the body surface shape measuring device according to Embodiment 9.

Mode for Carrying Out the Invention

[0010] (Outline of Embodiment) First, embodiments of the present invention will be listed and described. At least a part of the embodiments described below may be arbitrarily combined.

[0011] A body surface shape measuring device according to one aspect of the present invention includes a support portion that supports a portion of a human body in a sleeping posture other than the measurement portion, and one or a plurality of measurement portions into which the measurement portion fits. The measurement portion fits into the measurement portion, a portion other than the measurement portion is supported by the support portion, and the body surface shape of the measurement portion is measured.

[0012] According to the above configuration, it is possible to measure the body surface shape, including the bone shape, that matches the actual sleeping posture of a human body when it is relaxed (suspended). "Suspended state" refers to a state in which the entire body is relaxed, the limbs are extended and in a natural, relaxed position, breathing is not difficult, and the subject does not feel any discomfort. The protruding parts of the body surface shape are the parts where the user's weight (load) is applied, and at the same time, information on the distribution of body pressure can also be obtained. It is possible to create bedding such as pillows and mattresses in which the parts where the user's weight is applied are in close contact with the bedding, body pressure is well distributed, pain in the head, shoulders, neck, and lower back is suppressed, and the user feels no discomfort and gets a good night's sleep.

[0013] In the body surface shape measuring device described above, the device may have a plurality of support parts, and the plurality of support parts may be arranged in parallel such that the measuring part is interposed between the support parts.

[0014] With the above configuration, the support parts can be rearranged to match the part to be measured, the gaps between the support parts can be adjusted, and the width of the measurement area can be adjusted.

[0015] In the above-described body surface shape measuring device, a net may be stretched across the measuring section, and a net support section may be provided to support at least both sides of the net, with the portion to be measured facing the plane of the net, thereby measuring the body surface shape of the portion to be measured.

[0016] With the above configuration, the part to be measured can be supported by the net. Furthermore, when measuring the shape of the head, the hair can be made to adhere closely to the net, allowing for accurate measurement of the body surface shape.

[0017] The above-described body surface shape measuring device may also be equipped with a lifting mechanism for raising and lowering the net support portion.

[0018] With the above configuration, the height can be adjusted to properly suspend the part being measured. Furthermore, the height can be adjusted to suit the bedding being used by the user.

[0019] In the body surface shape measuring device described above, the width of the net may be expandable or contractible in the direction in which the support parts are arranged side by side.

[0020] With the above configuration, the width of the measuring section can be adjusted to suit the user's physique and body shape.

[0021] A body surface shape measuring device according to one aspect of the present invention comprises a support base and a molding material that is placed on the support base and molds the part of the human body to be measured while the person is lying down.

[0022] According to the above configuration, the mold can be used to obtain a body surface shape that includes the bone shape that matches the actual sleeping posture of the human body when the force is relaxed. This allows the parts of the user's body that bear weight to be in close contact with the bedding, distributing body pressure well, suppressing pain in the head, shoulders, neck, and lower back, and enabling the creation of bedding such as pillows and mattresses that provide a comfortable and good night's sleep.

[0023] In the above-described body surface shape measuring device, there may be a plurality of support bases, each of which can be raised and lowered independently, and the molding material may be placed on a support base that supports the part to be measured.

[0024] With the above configuration, the height of each support part can be adjusted so that the part being measured is suspended in mid-air while the user is lying down, and the height can also be adjusted to match the bedding the user is using.

[0025] One aspect of the present invention relates to bedding comprising a bedding body, a plurality of recesses and protrusions provided on the bedding body based on the shape of the body surface of a person in a suspended sleeping position, and a plurality of contact parts that fit into the plurality of recesses and make contact with the part of the person's body that bears the weight of the person in a sleeping position.

[0026] According to the above configuration, recesses are provided based on the body surface shape that matches the actual sleeping posture of a relaxed human body, and contact parts formed based on the body surface shape, which come into contact with the areas where weight is applied, are fitted into the recesses. Convex parts are provided on the bedding body corresponding to the recessed parts of the body surface shape. The contours of the body, including the areas where weight is applied, are in close contact with the bedding, so body pressure is well distributed, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also possible and requires fewer turns, resulting in good sleep.

[0027] One aspect of the present invention relates to bedding comprising a bedding body, a plurality of cut portions formed by cutting the bedding body based on the shape of the body surface in a suspended state when the person is sleeping, and a contact portion made of synthetic resin which is laminated on the portion of the cut portion that is subjected to the weight of the person, and which the portion comes into contact with.

[0028] According to the above configuration, synthetic resin is laminated onto a portion cut based on the body surface shape that matches the actual sleeping posture of a relaxed human body, forming a contact area where weight is applied. The contours of the body, including the load-bearing areas, adhere closely to the bedding, distributing body pressure well, resulting in a comfortable feel and suppressing stiffness in the shoulders and neck, as well as headaches. Turning over in bed is also smoother and requires fewer turns, leading to better sleep.

[0029] One aspect of the present invention relates to bedding which has a plurality of synthetic resin blocks arranged based on the shape of the body surface of a person in a suspended state while sleeping.

[0030] According to the above configuration, synthetic resin blocks are positioned based on the body surface shape that matches the actual sleeping posture of the human body when tension is relaxed. The areas where weight is applied are in close contact with the bedding, body pressure is well distributed, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also smoother and requires fewer turns, resulting in better sleep.

[0031] A method for manufacturing bedding according to one aspect of the present invention involves acquiring data relating to the surface shape of the part of the body to be measured while the human body is suspended in a sleeping position, and providing a plurality of recesses and protrusions on the bedding body based on the surface shape, and fitting contact parts into the recesses, which come into contact with the part of the human body that bears weight.

[0032] According to the above configuration, a recess is provided based on the body surface shape that matches the actual sleeping posture of a relaxed human body, and a contact portion formed based on the body surface shape, which comes into contact with the part where weight is applied, is fitted into the recess. A protrusion is provided on the bedding body corresponding to the recessed part of the body surface shape. The contours of the body, including the parts where weight is applied, are in close contact with the bedding, the body pressure is well distributed, there is no discomfort, stiffness in the shoulders and neck, and headaches are suppressed, and good sleep is obtained.

[0033] A method for manufacturing bedding according to one aspect of the present invention involves acquiring data relating to the surface shape of the part of the body to be measured while the human body is suspended in a sleeping position, cutting the bedding body based on the surface shape, and laminating synthetic resin on the load-bearing portion of the cut-out part to provide a contact portion that the load-bearing portion makes contact with.

[0034] Here, "lamination" is not limited to cases with multiple layers, but also includes cases with a single layer. According to the above configuration, synthetic resin is laminated onto a portion cut based on the body surface shape that matches the actual sleeping posture of a relaxed human body, forming a contact area where the weight-bearing parts make contact. The load-bearing parts and the bedding are in close contact, body pressure is evenly distributed, there is no discomfort, stiffness in the shoulders and neck, and headaches are suppressed, resulting in good sleep.

[0035] In the bedding manufacturing method described above, the synthetic resin may be laminated in such a way that it does not collapse under its own weight and the amount applied to the load portion is controlled so as to represent the shape of the body surface. According to the above configuration, the contact area is formed well.

[0036] A method for manufacturing bedding according to one aspect of the present invention involves acquiring data relating to the surface shape of the part of the human body to be measured while suspended in a sleeping position, and arranging a plurality of synthetic resin blocks of different materials, hardnesses, or heights based on the surface shape.

[0037] According to the above configuration, synthetic resin blocks are positioned based on the body surface shape that matches the actual sleeping posture of the human body when tension is relaxed. The areas where weight is applied are in close contact with the bedding, body pressure is well distributed, there is no discomfort, stiffness in the shoulders and neck, and headaches are suppressed, resulting in good sleep.

[0038] In the above-described method for manufacturing bedding, data relating to the body surface shape of the part to be measured may be obtained by molding the part to be measured.

[0039] According to the above configuration, the shape of the recess or cutout that serves as a receptacle for the user's body can be directly obtained as a mold for bedding such as pillows and mattresses, and the height data of the blocks can also be obtained, allowing bedding to be manufactured easily and quickly.

[0040] In the above-described method for manufacturing bedding, first data relating to the surface shape of the human body in a standing or sitting position may be acquired. The first data relating to the surface shape of the human body in a standing or sitting position and second data relating to the surface shape of the part of the human body to be measured in a suspended state in a sleeping position may be used as training data. The acquired first data may be input to a learning model that outputs the second data when the first data is input, thereby acquiring the second data of the human body. With the above configuration, the second set of data can be easily obtained.

[0041] A computer program according to one aspect of the present invention acquires data relating to the surface shape of a part of a human body to be measured while suspended in a sleeping position, and causes the computer to perform a process of cutting the bedding body based on the surface shape, laminating synthetic resin on the load-bearing portion of the cut-out part, and providing a contact portion that the load-bearing portion makes contact with.

[0042] A pillow according to one aspect of the present invention comprises a pillow body and a contact portion made of a different material from the pillow body, which is fitted into the pillow body and comes into contact with the head when the person is sleeping.

[0043] Here, even if two resins are of the same type, such as urethane resin, they are considered different materials if their density, specific gravity, hardness, etc., differ. According to the above configuration, by using materials with different hardness levels for the contact area compared to the pillow body material, it is possible to prevent the head from sinking too deeply and control the sleeping posture. In other words, good distribution of body pressure that conforms to the shape of the head and maintenance of the sleeping posture can be achieved. Furthermore, by selecting materials that can withstand changes over time for the contact area material, it is also possible to suppress the functional deterioration of the pillow over time.

[0044] In the pillow described above, the pillow body may have a recess that is open at the top, and the contact portion may be fitted into the recess. With the above configuration, the contact portion is securely fixed to the pillow body.

[0045] In the pillow described above, the contact portion may have a first through hole. For users with a protruding occipital region, the protrusion places a load on the pillow body, creating a gap between the periphery of the protrusion and the pillow body, resulting in a problem where the head, neck, and shoulder line is convex upwards. By having a first through-hole, the protrusion is contained within the first through-hole, absorbing the protrusion and resolving the above problem. The ideal head, neck, and shoulder line can be more easily formed for people with any occipital region shape.

[0046] In the pillow described above, the recess may have a second through hole, and the first through hole may communicate with the second through hole. According to the above configuration, the ideal alignment of the head, neck, and shoulders is more easily formed, and the breathability of the pillow is also improved.

[0047] The pillow described above may include a cylindrical portion that fits into the first through hole and the second through hole, and a first cover that covers the pillow body. According to the above configuration, the shapes of the first and second through holes can be maintained.

[0048] In the pillow described above, the curved shape of the peripheral edge of the first through hole in the contact portion may have a shape that corresponds to the bone shape of the head and the sleeping position. With the above configuration, the user's head and pillow are in close contact, body pressure is evenly distributed, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also smooth and requires fewer turns, resulting in better sleep.

[0049] The pillow described above may include an adjustment member positioned on the back side of the pillow body for adjusting the height, and a second cover that covers the adjustment member and the pillow body. With the above configuration, the height of the pillow can be easily adjusted while the movement of the adjustment member is suppressed.

[0050] In the pillow described above, the contact portion may include a three-layer structure consisting of a hard synthetic resin, a urethane resin, and a gel. The above configuration allows for a high degree of freedom in designing the distribution of body pressure along the shape of the head and maintaining the shape of the sleeping posture. By selecting materials that can withstand changes over time, the functional deterioration of the pillow over time can also be suppressed.

[0051] In the pillow described above, the contact portion may have three parts depending on the sleeping position. According to the above configuration, for example, by placing a contact area in the center that corresponds to sleeping on your back and contact areas on both sides that correspond to sleeping on your side, even if you start by sleeping on your back and then turn over to sleep on your side, you can achieve good distribution of body pressure according to the shape of your head and maintain the shape of your sleeping posture, resulting in good sleep. The same effect can be obtained even if you have three contact areas that correspond to sleeping on your side and change shape according to turning over.

[0052] In the pillow described above, the contact portion may be detachable. With the above configuration, the contact part can be used as a travel pillow, placed on a cushion and used for napping, etc.

[0053] A method for manufacturing a pillow according to one aspect of the present invention involves using the above-described body surface shape measuring device to acquire data relating to the body surface shape, including the bone shape of the head of a person in a sleeping position, forming a contact portion that comes into contact with the head in a sleeping position based on the data, and fitting the contact portion into the pillow body to manufacture the pillow.

[0054] According to the above configuration, a pillow that conforms to the user's actual sleeping posture is obtained. Since the pillow is manufactured based on the shape of the user's body surface, including the bone shape of the back of the head, where the most weight is applied to the pillow during sleep, or on the changes thereto based on the sleeping posture, the pillow can be made in close contact with the user's body, body pressure is distributed well, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also possible smoothly and requires fewer turns, resulting in better sleep.

[0055] The present invention will be described in detail below with reference to the drawings illustrating its embodiments. (Embodiment 1) Figure 1 is a plan view of the main body 2 and contact parts 4 and 5 according to Embodiment 1, Figure 2 is a perspective view of the main body 2 and contact parts 4 and 5, Figure 3 is an explanatory diagram for explaining the manufacturing method of contact part 4, Figure 4 is a plan view showing the main body 2 housed in the inner cover 6, Figure 5 is a rear view showing the main body 2 housed in the inner cover 6, Figure 6 is a plan view of the pillow 1 showing the inner cover 6 housed in the outer cover 9, Figure 7 is a rear view of the pillow 1 showing the inner cover 6 housed in the outer cover 9, Figure 8 is a cross-sectional view taken along line VIII-VIII in Figure 6, Figure 9 is a cross-sectional view taken along line IX-IX in Figure 6, Figure 10 is a plan view showing the pipe housing part 7, and Figure 11 is a plan view showing the plate part 8. The pillow 1 comprises a main body 2, contact parts 3, 4, and 5, an inner cover 6, a pipe housing part 7, a plate part 8, and an outer cover 9.

[0056] As shown in Figures 1 and 2, the main body 2 contains a synthetic resin material such as low-rebound urethane, and has a semi-circular shape in plan view, with a concave shape extending from both ends of the string towards the center. The main body 2 has a shape in the longitudinal center of the pillow 1 that approximates a relaxed sleeping posture, for example, when lying on one's back, where the spine forms a gentle S-shape. The shape of the main body 2 is preferably determined based on the bone shape from the head to the shoulders of an average person. However, the shape of the main body 2 is not limited to this case. The main body 2 has a recess 21 extending in the short direction in the center of the longitudinal direction of the pillow 1, and recesses 23, 23 extending in the short direction on both ends in the longitudinal direction.

[0057] A contact portion 3 is located in the center of the main body 2, and contact portions 4 and 5 are located on either side of it, fitted into recesses 21, 23, and 23, respectively. Contact portion 3 has a shape based on the bone structure of the user's head and the user's supine sleeping position. This shape is based on the bone structure from the back of the head to the neck and shoulders, the surface shape of the skull, and the surface shape that changes depending on the sleeping position. Contact portions 4 and 5 have shapes based on the bone structure of the user's head and the left side-lying position and the right side-lying position, respectively. The contact parts 3, 4, and 5 are formed based on the average head data (bone shape) of Japanese men and women, as described later. The above-mentioned users refer to male and female users. Multiple types of contact parts 3, 4, and 5 may be provided separately for males and females.

[0058] The contact portion 3 has a through hole 31 approximately in the center in the longitudinal direction. The recess 21 has a through hole 22 that communicates with the through hole 31. Alternatively, the through hole 22 may be omitted, and the lower end of the through hole 31 may be closed by the bottom surface of the recess 21. In the case of a user with a protruding occipital bone, the protrusion places a load on the pillow, creating a gap between the periphery of the protrusion and the pillow, resulting in a problem where the head, neck, and shoulder line is convex upwards. By having a through hole 31, the protrusion is contained within the through hole 31, resolving the above problem. The ideal head, neck, and shoulder line can be more easily formed even for people with different occipital bone shapes. Furthermore, if the through hole 31 extends to the through hole 90 of the outer cover 9, which will be described later, that is, if the hole penetrates from the front side to the back side, ventilation is good (see Figure 8).

[0059] The contact portions 4 and 5 have through holes 41 and 51 that correspond to the shape, size, and position information of the user's ear when lying on their side. The recesses 23 and 23 have through holes 224 and 24 that communicate with the through holes 41 and 51. The through-holes 41 and 51 are preferably shaped to be, for example, 0.5 cm to 2 cm larger than the outer edge of the user's ear. This makes it easier to turn over in bed, and the peripheral portions of the through-holes 41 and 51 of the contact parts 4 and 5 can effectively support the weight of the head. It is more preferable that the through-holes 41 and 51 are shaped to be 1 cm to 1.5 cm larger than the outer edge.

[0060] The ears protrude from the sides of the head, and when sleeping on one's side, the pressure on the head is concentrated on the ear area. Consequently, blood flow can be restricted at the ears, leading to increased tossing and turning to prevent blood stagnation, and sometimes causing the person to wake up before or after turning. Adopting unnatural postures to avoid crushing the ears can also cause stiffness in the neck or shoulder muscles. In this embodiment, the ears are housed in through-holes 41 and 51 that correspond to the shape, size, and position of the user's ears, and the load from the sides of the head and cheeks is distributed around the periphery of the through-holes 41 and 51, thus preventing this problem. While pillows that take ears into consideration have existed in the past, they have not solved the above problem because they have not taken into account the size, shape, and position of the ears based on the aforementioned head data. Alternatively, the through-hole 24 may be omitted, and the lower end of the through-hole 41 may be closed by the bottom surface of the recess 23.

[0061] The contact portion 3 comprises, for example, a first layer 32 made of gel, a second layer 33 made of urethane, and a third layer 34 made of a hard synthetic resin (see Figure 8). Examples of gels include elastic gels with a hardness of 0 to 12 as measured by the Japan Rubber Association standard SRIS0101. Examples of synthetic resins include PP, PE, PC, and ABS. The contact portion 4 comprises, for example, a first layer 42 made of gel, a second layer 43 made of urethane, and a third layer 44 made of a hard synthetic resin (see Figure 9). The contact portion 5 has the same configuration as the contact portion 4. The contact portions 3, 4, and 5 are not limited to having the three-layer structure described above. They may have a structure with four or more layers. In addition, to adjust the shape of the peripheral edges of the through holes 31, 41, and 51, adjustment plates designed to a predetermined shape may be placed above or below the three-layer structure described above. As these adjustment plates, urethane, gel, other synthetic resins, etc., having different densities, specific gravities, and hardnesses can be used. Multiple sets of the first, second, and third layers of the contact parts 3, 4, and 5 are provided, allowing each user to select the appropriate first, second, and third layer, and, if necessary, select an adjustment plate to customize the contact parts 3, 4, and 5.

[0062] The following describes how to manufacture the contact portion 4. For example, we could obtain average head size data for Japanese men and women from the National Institute of Advanced Industrial Science and Technology (AIST). As shown in Figure 3, the average head data (A data) 10 is rotated using reverse engineering software such as 3D CAD software to generate data for a left-facing, side-lying sleeping position, and three-dimensional shape data (B data) including the through hole 41 of the contact portion 4 is generated. Based on this B data based on the bone shape and sleeping position, the first layer 42, second layer 43, and third layer 44 of the contact portion 4 are manufactured by NC cutting or robot arm cutting, etc. They may also be manufactured by 3D printing. An adjustment plate for correction for each user may also be manufactured. For example, when sleeping on one's left side, if the angle between the cross-section obtained by cutting the head along a line passing through the longitudinal direction of the ear and the plane of the main body 2 is 45 degrees, the shape of the peripheral edge of the through-hole 41 is determined so that the height of the peripheral edge on the right side of the through-hole 41 is increased. Alternatively, an adjustment plate designed to increase the height of the peripheral edge on the right side of the through-hole 41 is placed on the upper side of the first layer 42 or on the lower side of the second layer 43.

[0063] Alternatively, a head model may be created based on the average head data described above, rolled on the main body 2, and sleeping posture data may be acquired by motion capture to generate B data. Alternatively, sleeping posture data of a person with an average build may be acquired by motion capture and combined with the head data to generate B data. Similarly, B data for contact parts 3 and 5 is generated, and contact parts 3 and 5 are manufactured. The fabricated contact parts 3, 4, and 5 are fitted into the recesses 21, 23, and 23 of the main body 2.

[0064] As shown in Figures 4 and 5, the main body 2, with its contact portions 3, 4, and 5 fitted into the recesses 21, 23, and 23, is covered by the inner cover 6. The inner cover 6 is bag-shaped. Various fibers can be used as the material for the inner cover 6, including natural fibers such as cotton, linen, silk, and wool, resin raw material fibers such as polyester, and processed natural raw material fibers such as cellulose fiber. However, it is not limited to fibers; resin raw materials or processed natural raw material products can also be used, as long as they can be used as a coating material. The inner cover 6 has three through holes 60 corresponding to the through holes 31, 41, and 51. A cylindrical portion 61 is provided in the central through-hole 60, aligned with the through-holes 31 and 22 of the contact portion 3. The cylindrical portion 61 has a sewn portion 62 at its upper end, which is sewn to the upper edge of the through-hole 60. The cylindrical portion 61 has a plurality of fixing portions 63 arranged radially at its lower end, which are fixed to the back surface of the inner cover 6, for example, by a hook-and-loop fastener structure. A cylindrical portion 61 is similarly provided in the through holes 60 at both ends.

[0065] As shown in Figures 6 and 7, with the pipe housing section 7 and plate section 8 positioned below the inner cover 6, the inner cover 6 is covered by the outer cover 9.

[0066] As shown in Figure 10, the pipe housing section 7 has a plurality of partitioned storage chambers 72 for storing materials such as urethane chips and flexible polyester pipes. The height of the pillow 1 is adjusted by adjusting the amount of material stored in the storage chambers 72. The pipe housing section 7 has three through holes 71 corresponding to the through holes 31, 41, and 51. Note that the number of storage chambers 72 is not limited to that shown in Figure 10. Height adjustment is achieved by incorporating a measuring tool into the computer program that can measure the distance between data points on the screen, and then measuring the required distance. When using the body surface shape measuring device 14 described later, the head is lifted by the measuring unit 15, making it easy to determine the height to be adjusted.

[0067] As shown in Figure 11, the plate portion 8 is a thin plate, for example, made of urethane, with a thickness of 1 to 2 cm, and the height of the pillow 1 is adjusted by stacking one or more of these plates. The plate portion 8 has a through hole 81 that extends in the longitudinal direction, corresponding to the through holes 31, 41, and 51. Conventional urethane plates for height adjustment tend to move easily and are thick overall to maintain their shape, but in the case of the plate portion 8 of this embodiment, the through hole 81 is present, and the movement of the plate portion 8 is restrained by the cylindrical portions 61 and 91. Since the movement of the plate portion 8 can be restrained, the plate portion 8 can be positioned at the desired location.

[0068] The outer cover 9 is bag-shaped. The outer cover 9 has three through holes 90 corresponding to the through holes 31, 41, and 51. Various fibers can be used as the material for the outer cover 9, including natural fibers such as cotton, linen, silk, and wool, resin raw material fibers such as polyester, and processed natural raw material fibers such as cellulose fiber. However, it is not limited to fibers; resin raw materials or processed natural raw material products can also be used, as long as they can be used as a coating material. A cylindrical portion 91 is provided in the central through-hole 90, aligned with the cylindrical portion 61 of the inner cover 6. The cylindrical portion 91 is sewn to the upper edge of the through-hole 90. The cylindrical portion 91 has a plurality of fixing portions 92 arranged radially at its lower end, and the fixing portions 93 are fixed to the back surface of the outer cover 9, for example, by a hook-and-loop fastener structure. A cylindrical portion 91 is similarly provided in the through holes 90 at both ends. The cylindrical portion 91 may be provided with multiple lengths and widths of gussets, depending on the user.

[0069] As shown in Figure 8, the through holes 22, 60, 71, 81, and 90 of the main body 2, inner cover 6, pipe housing section 7, plate section 8, and outer cover 9 are connected to the through hole 31. Note that the cylindrical sections 61 and 91 are omitted in Figure 8. As shown in Figure 9, the through holes 24, 60, 71, 81, and 90 of the main body 2, inner cover 6, pipe housing section 7, plate section 8, and outer cover 9 are connected to the through hole 41. Note that the cylindrical sections 61 and 91 are omitted in Figure 9.

[0070] According to this embodiment, the contact parts 3, 4, and 5 provide good distribution of body pressure along the shape of the head and maintain the shape of the sleeping posture. Furthermore, by using materials that can withstand changes over time for the contact parts 3, 4, and 5, the functional deterioration of the pillow over time can be suppressed. For example, the ideal sleeping position is when sleeping on your back, with the axis of the neck and chin forming an angle of approximately 15 degrees with the top of the bed. When sleeping on your side, the head, neck, spine, and hip bones are connected in a straight line. Many people deviate from this ideal sleeping position for various reasons and cannot achieve it. Some even find it uncomfortable to adopt the ideal sleeping position. With appropriate guidance from a specialist, it becomes possible to gradually adjust the angle and correct the current sleeping position to the ideal sleeping position for the user. For example, by increasing the angle by 2 degrees, then 4 degrees, and checking the S-curve of the neck and breathing, it is possible to move closer to the ideal sleeping position that the user should naturally be in, enabling better sleep. In conventional methods, when providing such guidance, a new product would have to be purchased each time the angle is changed. However, in this embodiment, it is only necessary to select from multiple contact parts 3, 4, and 5, or to insert an adjustment plate above or below the contact part.

[0071] (Embodiment 2) Figure 12 is a plan view of the main body 2 and contact portion 4 according to Embodiment 2. In the figure, the same parts as in Figure 1 are denoted by the same reference numerals and detailed descriptions are omitted. In the main body 2 according to Embodiment 2, three contact portions 4 are fitted together. The central contact portion 4 has a shape corresponding to a sleeping position when the angle between the cross section cut by a line passing through the longitudinal direction of the ear in the head data 10 and the plane of the main body 2 is 90 degrees, similar to the head data 10 in Figure 3. The right contact portion 4 in Figure 12 has a shape corresponding to a sleeping position when the angle between the cross section and the plane of the main body 2 is 45 degrees. The left contact portion 4 in Figure 12 has a shape corresponding to a sleeping position when the angle between the cross section and the plane of the main body 2 is 135 degrees. Furthermore, the case is not limited to situations where the three contact portions 4 have different shapes; the shapes of the left and right contact portions 4 may be adjusted using the adjustment plates described above.

[0072] As described above, for users who sleep on their left side, the head initially rests against the central contact area 4 in the 90-degree position. When adopting the 45-degree position, the head rests against the right contact area 4. When adopting the 135-degree position, the head rests against the left contact area 4. A comfortable sleeping position can be achieved depending on the angle of side sleeping. By having a pillow shape that conforms to the user's sleeping position during the initial period of falling asleep, unnecessary tossing and turning caused by impaired blood circulation is reduced, thereby improving sleep quality.

[0073] (Embodiment 3) In the pillow 1 according to Embodiment 3, the contact portion 3 is configured to be detachable. Figure 13 is a perspective view of the contact portion 3. The contact part 3 can be removed, and it can be used as a travel pillow, allowing you to rest your head against it while it's placed against a train or airplane seat. Additionally, you can place the contact part 3 on top of the cushion and take a nap.

[0074] (Embodiment 4) In Embodiment 4, the contact parts 3, 4, and 5 are manufactured based on B data derived from the B-data obtained by measuring the bone shape of each user, generating sleeping posture data based on the A data related to the bone shape, and measuring the B-data derived from the sleeping posture data. Figure 14 is a block diagram showing the bedding manufacturing system 13 according to Embodiment 4. The bedding manufacturing system 13 includes an acquisition device 11 that acquires imaging data, and a PC 12 that acts as a generation device that extracts A data related to the bone shape of the user's head, as well as the shape, size, and position of the ears from the imaging data, and generates B data for forming contact parts 3, 4, and 5. Examples of acquisition devices 11 include 3D scanners. Cameras may also be used as acquisition devices 11. Alternatively, motion capture may be used to acquire positional information of the head when the person turns over to sleep on their side, and contact parts 4 and 5 may be manufactured based on the A data and positional information.

[0075] The PC12 comprises a control unit 121, a storage unit 122, an input unit 124, and an interface unit 125. These units are connected to each other via a bus so that they can communicate with one another. The input unit 124 receives imaging data from the acquisition device 11. The interface unit 125 is configured, for example, with a LAN interface and a USB interface, and communicates with the acquisition device 11 via wired or wireless connection. Data can be transferred using a USB memory stick or the like, not just wired or wireless.

[0076] The storage unit 122 is composed of, for example, a hard disk drive (HDD) and stores various programs and data. For example, the pillow manufacturing program 123 is stored in the storage unit 122. The pillow manufacturing program 123 is provided stored on a computer-readable recording medium 16, such as a CD-ROM, DVD-ROM, or USB memory, and is stored in the storage unit 122 by installing it on the PC 12. Alternatively, the pillow manufacturing program 123 may be obtained from an external computer (not shown) connected to a communication network and stored in the storage unit 122. The storage unit 122 may also store a mat manufacturing program for manufacturing mats.

[0077] Figure 15 is a perspective view showing the body surface shape measuring device 14, and Figure 16 is a schematic diagram showing the state in which the body surface shape of the user in a sleeping position is acquired using the body surface shape measuring device 14. The body surface shape measuring device 14 comprises box-shaped support parts 141, 141, 141 that support the user in a lying position, and a measuring part 15. The measuring unit 15 comprises a base 151, columnar sections 152, 152 that can move up and down by actuators, a rectangular net 153, and a net support section 154. The net support section 154 is provided at the upper ends of the columnar sections 152, 152 and supports both sides of the net 153. It comprises support plates 154a, 154a that move up and down in accordance with the up and down movement of the columnar sections 152, 152, and a top plate 154b that has a U-shape in plan view and is attached to the support plates 154a, 154a.

[0078] The net 153 is a mesh-like structure, rectangular in shape, and attached to the inner circumference of the U-shape of the net support 154. Various fibers can be used as the material for the net 153, including natural fibers such as cotton, linen, silk, and wool, resin fibers such as polyester, and processed natural fiber fibers such as cellulose fiber. However, it is not limited to fibers; resin materials or processed natural materials can also be used, as long as they can be used as a coating material. As shown in Figure 16, the net 153 is attached to the net support 154 with tension such that it adheres tightly to the head, preventing the head, which protrudes horizontally from the torso, from drooping when measuring the body surface shape, including the bone structure of the head. Excessive tension is undesirable, as it will not conform to the shape and may cause pain to the person being measured. It is preferable to loosen the tension moderately so that it gently conforms to the body, but this is not essential as measurement is still possible. The mesh should preferably be large enough to prevent hair or flesh from showing through. The mesh size should more preferably be 4 mm or less on each side, and even more preferably about 2 mm on each side. The net 153 is preferably transparent enough to allow the surface of the object being measured to be seen, and is more preferably thin, but is not limited to that. The reason why transparency is preferable is to make it easier for the person being measured to recognize that they are being measured when they look at the measurement screen; however, it is not essential. The thickness affects the measured shape; the thicker it is, the more it will be distorted. However, measurement is still possible, so making it thinner is not essential.

[0079] The support portion 141 is not limited to a box shape. The number of support portions 141 is not limited to three. The support portions 141 are arranged to correspond to the parts of the user's body to be measured. If the part to be measured is the head, as shown in Figure 16, the measuring unit 15 is positioned on one end side of the support units 141, 141, 141 which are arranged in the longitudinal direction, so that the head faces the net 153. If the part to be measured is the waist, the measuring unit 15 is positioned facing the waist, and the support units 141, 141, 141 are positioned so as to sandwich the measuring unit 15 between them.

[0080] The shape of net 153 is not limited to a rectangular shape. It is preferable that net 153 be thin so that the bone shape can be clearly recognized. The support section 141 may, for example, be equipped with several samples of bedding or similar items that the user uses at home, and these can be placed on the support section 141 to allow measurements to be taken in a sleeping position similar to that at home.

[0081] As shown in Figure 16, when the head is positioned facing the net 153 of the measurement unit 15, the portion from the shoulders to the top of the head protrudes from the support unit 141 so as to float in the air, while the rest of the user's body is supported by the support units 141, 141, 141. Then, with the net 153 adjusted to conform to the bone shape from the head to the base of the neck in a sleeping position, the body surface shape, including the bone shape, is measured by the acquisition device 11. It is preferable to adjust the net 153 by raising and lowering the net support unit 154 while checking whether breathing is easy and whether there are any areas that cause discomfort or suffocation while sleeping, in order to determine the position and posture.

[0082] During measurement, the net support section 154 is raised or lowered to adjust the relative height between the support section 141 and the measuring section 15. The pillow 1 is made to allow the user to sleep in a natural position with a relaxed spinal curve, taking into account the mattress and futon used by the user. The body surface shape measuring device 14 can measure the nerves from the back of the head to the shoulders, the shape of the neck bones, and the surface shape of the skull. When the gap between the skull, neck bones, and nerves is comfortably filled, a person can sleep peacefully and easily turn over in their sleep. This gap varies from person to person and is small, but it is a very important part when falling asleep.

[0083] As described above, when manufacturing the pillow 1 using the body surface shape measuring device 14, A data related to the body surface shape, including the bone shape of each user's head, is acquired. PC12 rotates the A data using reverse engineering software such as 3D CAD software to generate data for supine and lateral sleeping positions, and generates 3D shape data (B data) for the contact parts 3, 4, and 5. Based on this B data, which is based on bone shape and sleeping position, the first, second, and third layers of the contact parts 3, 4, and 5 are manufactured by cutting using NC cutting, robot arm cutting, or 3D printing. The adjustment plate may be manufactured and adjusted for each user. Alternatively, the changes in the body surface shape according to the sleeping posture may be acquired as data, and this data may be converted into output data (B data) such as STL data and surface data by applying reverse engineering to create the contact portion 3. The fabricated contact parts 3, 4, and 5 are fitted into the recesses 21, 23, and 23 of the main body 2 to manufacture the pillow 1.

[0084] Instead of using the body surface shape measuring device 14, the user's standing or sitting position may be imaged with a camera to obtain data on the bone shape of the head. When measuring the shape of the temporal region, the bone shape around the ears, which is particularly important for distributing body pressure, and similarly for the occipital region, the bone shape from the top of the occipital region to the neck, may be measured if they are not clearly visible due to hair. In such cases, a swimming cap or similar device that can hold or tie back the hair may be used for measurement. When a person is standing, they exert force to support their spine, and when they are lying down, they are relaxed and that force is released. Therefore, the shape of a person's bones and muscles differs between standing or sitting positions and lying down positions. The human spine curves to support an upright posture, and this is a physiological phenomenon where muscle force works to support the body. Therefore, if the depth of the neck curvature is measured in a standing or sitting position and reflected in the shape of the contact area, there is a risk of discomfort when lying down. It is preferable to acquire A data using the body surface shape measuring device 14. When using the body surface shape measuring device 14, it is possible to acquire the shape from the head to the shoulders in a suspended state, i.e., in a relaxed, suspended state while lying on one's back or side.

[0085] It is known that turning over in sleep helps humans regulate body temperature, recover from physical and mental fatigue, improve immunity, organize memories, and repair internal tissues. When using the body surface shape measuring device 14, it is necessary to take measurements in a position that makes it easy to turn over in sleep. Experiments have confirmed that the most comfortable sleeping position for turning over is when, when sleeping on your side, the head, neck, spine, and hip bones are parallel to the bottom surface of the bedding and connected in as straight a line as possible, and when sleeping on your back, the body from the neck down is connected in as straight a line as possible to the bottom surface of the bedding, with the head slightly angled upwards from the straight line. A test was conducted to determine the angle that allows for easy turning over in bed. When the angle between the axis of the head and the horizontal line was in the range of 10 to 20 degrees, a comfortable pillow could be provided to all subjects. After the user assumes a sleeping position, the height of the net support section 154 is adjusted and measured based on the 10 to 20-degree range to achieve a comfortable angle. It is preferable to then make further adjustments using the pipe housing section 7 and board section 8 when manufacturing the pillow 1.

[0086] As mentioned above, the shape of bones and muscles differs between standing or sitting positions and lying down positions. In this embodiment, since A data is acquired with the user's head suspended in mid-air from the torso while lying down, a pillow 1 that matches the actual shape of the sleeping position can be manufactured.

[0087] When manufacturing a pillow 1 for a user who sleeps face down, the body surface shape measuring device 14 is used to acquire A data related to the bone shape of the face from both cheeks and the bone shape from the neck to the chest when the user is lying face down. Then, data related to the sleeping posture is acquired for each user, and B data is generated based on the acquired data to manufacture the contact area. The contact area for face down sleeping has a shape that allows the chin to be rested in the upper center of the main body 2. The pillow 1 may be made exclusively for face down sleeping, or a contact area for side sleeping may be manufactured to accommodate side sleeping. For users with symptoms of sleep apnea, data related to the user's ideal sleeping position, where the base of the tongue does not sink and the upper airway does not narrow, will be collected in cooperation with a physician or other medical professional to generate B data.

[0088] When measuring a part of the body to be measured other than the head, such as the waist, using the body surface shape measuring device 14, the top plate 154b is removed, the measuring unit 15 is positioned so that the part to be measured faces the net 153, and the parts other than the part to be measured are supported by the support unit 141, and the body surface shape of the part to be measured is measured.

[0089] (Embodiment 5) Figure 17 is a perspective view showing the body surface shape measuring device 14 according to Embodiment 5, and Figure 18 is a schematic diagram showing the state in which the body surface shape of the user in a lying position is acquired using the body surface shape measuring device 14. In Figures 17 and 18, the same parts as in Figures 15 and 16 are denoted by the same reference numerals and detailed explanations are omitted. The body surface shape measuring device 14 comprises a head measuring section 150, a base 158, column sections 157, 157 that are movable vertically by actuators and slidable horizontally, a net 156, net support sections 155, 155, support section 159, and a base 160. For example, there are six nets 156 and five support sections 159. The nets 156 are stretched across the measuring section between the support sections 159, 159. The number and arrangement of the nets 156 and support sections 159 are not limited to the case shown in Figure 17. The net support sections 155, 155 are provided at the upper ends of the column sections 157, 157, supporting both sides of the net 156, and moving up and down in accordance with the vertical movement of the column sections 157, 157. The tension and deflection of the net 156 are adjusted according to the horizontal sliding movement of the column sections 157, 157.

[0090] Net 156 is a mesh-like structure with a rectangular shape. Various fibers can be used as materials for Net 156, including natural fibers such as cotton, linen, silk, and wool, resin-based fibers such as polyester, and processed natural fibers such as cellulose fiber. However, it is not limited to fibers; resin-based materials or processed natural materials can also be used, as long as they can be used as a coating material.

[0091] The head measurement unit 150 has the same configuration as the measurement unit 15 according to Embodiment 4.

[0092] The support section 159 is box-shaped and rests on the base 160. The support section 159 may be made of a material that can support body weight and maintain a natural sleeping posture, such as a resin like urethane or gel, a recycled material made of fibers, feathers, cellulose fiber, etc., which has cushioning properties and can maintain a sleeping posture. The platform 160 may be equipped with casters and may be height-adjustable. The support portion 159 supports the parts of the user's body that are not measured. As shown in Figure 18, the head measuring section 150 is positioned at one end of the nets 156 that are arranged in the longitudinal direction, so that the head faces the net 153. The user's head and neck are positioned facing the net 153. Starting from the head, each net 156 is positioned opposite the following areas: from the neck to the shoulder blades, from the shoulder blades to the hollow of the waist, from the hollow of the waist to the lower part of the buttocks, from the lower part of the buttocks to the lower part of the knees, from the lower part of the knees to the ankles, and from the ankles to the heels. The parts of the user to be measured, to which the net 156 is positioned opposite, are not limited to the above case. The shape of the net 156 is not limited to a rectangular shape. It is preferable that the net 156 be thin so that the body surface shape can be clearly recognized.

[0093] In Figure 17, the base 151 is shown to be cut off at the foot end, but as shown in Figure 18, the base 151 extends to the foot end. The base 151 has a guide section 161 for the acquisition device 11 in the longitudinal direction at the center of the shorter side. As shown in Figure 18, when the user lies supine on the body surface shape measuring device 14, the acquisition device 11 moves from the head side to the heel side, acquiring the body surface shape of the parts to be measured, from the head to the neck, from the neck to the shoulder blades, from the shoulder blades to the hollow of the waist, from the hollow of the waist to the lower part of the buttocks, from the lower part of the buttocks to the lower part of the knees, from the lower part of the knees to the ankles, and from the ankles to the heels. For example, casters can be attached to the acquisition device 11, and the acquisition device 11 can be moved along the guide section 161 to photograph the entire body at once. It is preferable, but not limited to, that the casters be able to move back and forth along the same route like a railway track. The acquisition device 11 may also be moved by an actuator. The acquisition device 11 can be made mobile using methods other than casters; for example, it can be mounted on a drone, pulley, radio control device, trolley, conveyor belt, etc., and used for photographing subjects in a lying-down position. Essentially, all you need to do is move the camera underneath the user while they are lying down and take a picture.

[0094] Each part to be measured is supported by a net 156 and suspended, allowing the body surface shape to be acquired. The body surface shape obtained matches the actual supine sleeping position of a human body with relaxed tension. The parts that protrude below the surface of the body are the areas where body weight (pressure, load) is applied, and information on the pressure distribution can be obtained in good condition. A sheet for measuring body pressure distribution may be placed on net 156 to measure body pressure distribution in addition to body surface shape.

[0095] The body surface shape when the user is sleeping on their side or on their stomach is acquired in the same manner. To acquire the body surface shape when the user is sleeping on their side without distortion, the acquisition device 11 may be made to move not only in the center but also along the right and left edges. Three acquisition devices 11 may be provided, and the three acquisition devices 11 may be moved simultaneously in parallel.

[0096] Multiple nets 156 may be integrated into one.

[0097] As shown in Figure 18, when the head is positioned facing the net 153 of the head measurement unit 150, the portion from the neck to the top of the head is made to protrude as if floating in the air, while the rest of the user's body is supported by the net 156 and support unit 159. Then, with the net 153 adjusted to conform to the bone shape from the head to the base of the neck in a sleeping position, the body surface shape, including the bone shape, is measured by the acquisition device 11. When adjusting the net 153, it is preferable to raise and lower the net support unit 154 to determine the position and posture while checking whether breathing is easy, and whether there are any parts that cause discomfort or suffocation while sleeping. It is also preferable that the height allows for turning over in bed without any motion or effort. For parts of the body to be measured other than the head, the net 156 should be adjusted to conform to the shape of the body surface in a sleeping position. It is also preferable to adjust the height and lateral position of the column 157.

[0098] During measurement, the net support section 154 is raised and lowered to adjust the relative height between the net 156 and support section 159 and the head measurement section 150. The mattress 17 is made to allow the user to sleep in a natural position with a relaxed spinal curve, taking into account the mattress or other bedding used by the user.

[0099] The body surface shape measuring device 14 of this embodiment can accurately measure the body surface shape from the head to the heel. A pillow 1 can be made that comfortably fills in the gaps between the skull, neck bones, and nerves. A mat 17, described later, can be made that fits the contours of the user's body surface shape, allowing the spine to form a gentle S-shape when sleeping on one's back, and enabling a sleeping posture that is not strained. When there is no gap between the body surface shape and the bedding, a person can sleep with peace of mind and easily turn over in their sleep.

[0100] Figure 19 is a plan view showing a mat 17 made using the body surface shape measuring device 14 of this embodiment. The mat 17 comprises a main body 170, a recess 171 based on the body surface shape in a supine sleeping position, a recess 172 based on the body surface shape in a side-lying position, a contact portion 18 that fits into the recess 171, and a contact portion 19 that fits into the recess 172. The main body 170 includes, for example, a synthetic resin material such as low-rebound urethane. The main body 170 has a shape that approximates a sleeping position in which the spine forms a gentle S-shape when lying on one's back, and where no force is applied. The shape of the main body 170 has recesses and protrusions based on the body surface shape of each user, which is measured individually by a body surface shape measuring device 14. Mat 17 has a thickness of, for example, 5-8 cm and can be used as a mat on its own or placed on top of other bedding.

[0101] The contact portion 18 contacts the protrusion at the base of the neck, the scapula, the protrusion at the lower angle of the scapula, the spine, the back of the elbow, the upper protrusion of the hip bone, the central part of the buttocks (center of the hip bone), both ends of the buttocks, and the heel. The contact portion 18 has a through hole 181. The peripheral edge of the through hole 181 has a curved shape that conforms to the shape of the body surface of the part of the human body that is in contact with it. The contact portion 19 contacts the outer part of the scapula, the elbow, both ends of the thigh, and the knee. The contact portion 19 has a through hole 191. The periphery of the through hole 191 has a curved shape that conforms to the shape of the body surface it contacts. In Figure 19, the contact portion 18 and contact portion 19 are depicted as perfect circles, but in reality, they have a circumferential shape that matches the shape of the body surface they come into contact with. In Figure 19, the contact portion 19, which is shown to be located on the inside of the hand, comes into contact with both ends of the thigh when sleeping on one's side. The protruding parts are positioned to correspond to the recessed areas of the measured body surface shape, specifically from the neck to the shoulders, between the shoulder blades, from the back to the waist, the knees, and the ankles, and they come into contact with these areas. Furthermore, if the recessed and convex parts fit too precisely to the shape of the body surface, it will become difficult to turn over in your sleep, so it is preferable to make them slightly smaller.

[0102] Figure 20 is a partial cross-sectional view of mat 17. The contact portion 18 is fitted into the recess 171. The contact portion 18 has a through hole 181, and the recess 171 has a through hole 170a that communicates with the through hole 181. The contact portion 18 comprises, for example, a first layer 182 made of gel, a second layer 183 made of urethane, and a third layer 184 made of a hard synthetic resin. Examples of gels include elastic gels with a hardness of 0 to 12 as measured by the Japan Rubber Association standard SRIS0101. Examples of synthetic resins include PP, PE, PC, and ABS. The contact portion 18 is manufactured separately from the main body 170 and fits into a recess 171 provided in the main body 170. The other contact parts 18 and 19 have a similar configuration. The contact portions 18 and 19 are not limited to having the three-layer structure described above. They may have a structure with four or more layers. In addition, to adjust the shape of the peripheral edges of the through holes 181 and 191, adjustment plates designed to a predetermined shape may be placed above or below the three-layer structure described above. As these adjustment plates, urethane, gel, other synthetic resins, etc., having different densities, specific gravities, and hardnesses can be used. As mentioned above, a protrusion is formed from the back to the waist.

[0103] The main body 170 is covered by an inner cover 6 and an outer cover 9. The inner cover 6 is bag-shaped. Various fibers can be used as the material for the inner cover 6, including natural fibers such as cotton, linen, silk, and wool, resin raw material fibers such as polyester, and processed natural raw material fibers such as cellulose fiber. However, it is not limited to fibers; resin raw materials or processed natural raw material products can also be used, as long as they can be used as a coating material. The inner cover 6 has through holes 60 that correspond to the through holes 170a. The outer cover 9 is bag-shaped. The outer cover 9 has through holes 90 corresponding to through holes 170a. Various fibers can be used as the material for the outer cover 9, including natural fibers such as cotton, linen, silk, and wool, resin raw material fibers such as polyester, and processed natural raw material fibers such as cellulose fiber. However, it is not limited to fibers; resin raw materials or processed natural raw material products can also be used, as long as they can be used as a coating material. A plate portion 8 is inserted between the lower inner cover 6 and the outer cover 9. The plate portion 8 is a thin plate, for example, made of urethane, with a thickness of 1 to 2 cm, and one or more of these plates are stacked to adjust the height of the mat 17. The plate portion 8 has through holes 81 that extend in the longitudinal direction and correspond to the through holes 170a.

[0104] According to the above configuration, recesses 171 and 172 are provided based on the body surface shape that matches the actual sleeping posture of a relaxed human body. Contact parts 18 and 19, formed based on the body surface shape and in contact with the parts where weight is applied, are fitted into the recesses 171 and 172. Convex parts are provided on the main body 170 corresponding to the recessed parts of the body surface shape. The contours of the body, including the parts where weight is applied, are in close contact with the bedding, body pressure is well distributed, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also possible and requires fewer turns, resulting in good sleep.

[0105] Figure 21 is a cross-sectional view showing the buttock portion of the mat 17 of Modification 1. In the figure, parts identical to those in Figure 20 are denoted by the same reference numerals, and detailed explanations are omitted. In the modified mat 17, the main body 170 is cut to form a recess 171, and the third layer 184, the second layer 183, and the first layer 182 are laminated in this order on the periphery of the recess 171 to form a contact portion 18.

[0106] According to the above configuration, synthetic resin is laminated into recesses 171 and 172 obtained by cutting based on the body surface shape that matches the actual sleeping posture of a relaxed human body, forming contact parts 18 and 19 that come into contact with the weight-bearing parts. The load-bearing parts and the bedding are in close contact, body pressure is well distributed, there is no discomfort, and stiffness in the shoulders and neck, as well as headaches, are suppressed. Turning over in bed is also possible smoothly and requires fewer turns, resulting in good sleep.

[0107] The following describes the method for creating the mat 17 in the modified example 1. Figure 22 is a block diagram of the bedding manufacturing system 25 according to Embodiment 5. The bedding manufacturing system 25 includes an acquisition device 11 for acquiring imaging data, a PC 12 as a generation device that extracts A data related to the body surface shape from the imaging data and generates B data for forming contact parts 18 and 19, and a 3D printer 30 for manufacturing the contact parts 18 and 19 of the mat 17 based on the B data. Examples of acquisition devices 11 include 3D scanners. Cameras may also be used as acquisition devices 11. Alternatively, motion capture may be used to acquire positional information of the user when they turn over to sleep on their side, and contact parts 18 and 19 may be manufactured based on the A data and positional information.

[0108] The PC12 comprises a control unit 121, a storage unit 122, an input unit 124, and an interface unit 125. These units are connected to each other via a bus so that they can communicate with one another. The input unit 124 receives imaging data from the acquisition device 11. The interface unit 125 is configured, for example, with a LAN interface and a USB interface, and communicates with the acquisition device 11 via wired or wireless connection. Data can be transferred using a USB memory stick or the like, not just wired or wireless.

[0109] The storage unit 122 is composed of, for example, a hard disk drive (HDD) and stores various programs and data. For example, the mat manufacturing program 126 is stored in the storage unit 122. The mat manufacturing program 126 is provided stored on a computer-readable recording medium 16, such as a CD-ROM, DVD-ROM, or USB memory, and is stored in the storage unit 122 by installing it on the PC 12. Alternatively, the pillow manufacturing program 123 may be obtained from an external computer (not shown) connected to a communication network and stored in the storage unit 122. The pillow manufacturing program may also be stored in the storage unit 122.

[0110] Based on the A data, PC12 generates data for supine and lateral sleeping positions using reverse engineering software such as 3D CAD software, and generates 3D shape data (B data) for the contact parts 18 and 19. Based on this B data, the first, second, and third layers of the contact parts 18 and 19 are manufactured by 3D printing or the like. Alternatively, the changes in the body surface shape according to the sleeping posture may be acquired as data, and this data may be converted into output data (B data) such as STL data and surface data by applying reverse engineering to create the contact parts 18 and 19.

[0111] Figure 23 is a flowchart showing the procedure for mat manufacturing by the control unit 121 of PC12. The control unit 121 acquires the user's imaging data from the acquisition device 11 of the body surface shape measuring device 14, and acquires B data for forming the contact parts 18 and 19 based on this A data (S1). When the body surface shape measuring device 14 acquires the user's body surface shape while lying on their side, it is not necessary to generate data for the side-lying body surface shape from data for the supine body surface shape.

[0112] The control unit 121 cuts the main body 170 based on the B data, and the recess 171 for the contact portion 18 , and a recess 172 for the contact portion 19 is generated (S2). The control unit 121 uses a 3D printer 30 to extrude synthetic resin onto the periphery of the recesses 171 and 172, thereby stacking the first layer, second layer, third layer, etc. (S3). In this case, it is preferable to laminate the material while controlling the amount of synthetic resin discharged, as determined by algorithmic analysis, so that it does not collapse under its own weight and represents the surface shape of the body. Instead of the 3D printer 30, a robotic arm may be used to extrude the synthetic resin.

[0113] Similarly to the above, mat 17 in Figure 20 acquires A data and B data related to the body surface shape, and recesses 171 and 172 are formed in the main body 170. Based on the B data, contact portions 18 and 19 are manufactured and fitted into recesses 171 and 172. Synthetic resin may be extruded into recesses 171 and 172 to form contact portions 18 and 19.

[0114] Figure 24 is a perspective view showing the mat 17 of modified example 2. The mat 17 in the modified example 2 is made up of multiple synthetic resin blocks 20 with different materials, hardnesses, or heights, arranged based on the body surface shape obtained by the body surface shape measuring device 14. The number of blocks 20 is not limited to the case shown in Figure 24. Block 20 may be made of gel or urethane, and may be filled with wool, feathers, cotton, or horsehair. Based on the body surface shape and pressure distribution acquired by the body surface shape measuring device 14, the material, hardness, or height of each block 20 is adjusted to generate a surface shape for the mat 17 that fits the user's body surface shape as a whole.

[0115] According to the mat 17 of the modified example 2, the synthetic resin blocks 20 are positioned based on the body surface shape that matches the actual sleeping posture of the human body when the force is relaxed. The load-bearing parts and the mat 17 are in close contact, body pressure is well distributed, there is no discomfort, stiffness in the shoulders and neck, and headaches are suppressed, resulting in good sleep.

[0116] Figure 25 is a perspective view showing the portion of the body surface shape measuring device 14 in modified example 3 that faces the part being measured. The portion of the body surface shape measuring device 14 in the modified example 3 that faces the part to be measured includes a net 156, a base 164, column portions 162, 162 that can move up and down by actuators and slide in the direction in which the support portion 159 is installed parallel to each other, and net support portions 163, 163. The net support sections 163, 163 are provided at the upper ends of the column sections 162, 162 and support both sides of the net 156, moving up and down in accordance with the vertical movement of the column sections 162, 162. The tension, deflection, and width of the net 156 are adjusted according to the sliding of the column sections 162, 162 in the front-rear direction on the base 164. According to the above configuration, the width of the measuring section, across which the net 156 is stretched, can be adjusted to suit the user's physique and body shape. The configuration for stretching the width of net 156 is not limited to the case described above.

[0117] Figure 26 is a plan view showing the body surface shape measuring device 14 of the modified example 4. The body surface shape measuring device 14 of the modified example 4 comprises a rectangular plate portion 167, a plurality of measuring portions 165 into which the user's part to be measured fits, and four column portions 166 that support the plate portion 167. The plate portion 167 can be made of polyurethane, cotton futon, latex, polyester, or the like. For example, the measuring sections 165 are provided to correspond to the head, the protrusion at the base of the neck, the protrusion at the lower angle of the scapula, the protrusion on the upper side of the hip bone, and the central part of the hip bone (including the sacrum). The number of measuring sections 165 is not limited to five. There may be one or six or more. The position of the measuring sections 165 is also not limited.

[0118] With the above configuration, the surface shape of the body part to be measured while suspended in a lying position can be obtained with a simple setup. The plate portion 167 may be divided into a portion having a measuring portion 165 and a plurality of support portions that support portions other than the portion to be measured. If the measuring portion 165 is the gap between the support portions and a net is stretched across it, it corresponds to the body surface shape measuring device 14 in Figure 17. The body surface shape measuring device 14 in Figure 26 may be provided in multiple units with different positions and sizes of the measuring section 165 to match the user's height.

[0119] (Embodiment 6) Figure 27 is a cross-sectional view showing the body surface shape measuring device 14 according to Embodiment 6. Components identical to those in Figure 18 are denoted by the same reference numerals, and detailed descriptions are omitted. The body surface shape measuring device 14 comprises a head measuring unit 150, a base 158, columnar sections 157, 157 that can slide in the front-rear and left-right directions by actuators, a net 156, net support sections 155, 155, support section 159, and a base 160. For example, there are six nets 156 and five support sections 159. The net support sections 155 are provided at the front ends of the columnar sections 157, support both sides of the nets 156, and move in accordance with the front-rear movement of the columnar sections 157 and in accordance with the left-right movement of the columnar sections 157. The number and arrangement of the nets 156 and support sections 159 are not limited to those shown in Figure 17. The head measuring unit 150 comprises a base 151, a column 152 that can move in the front-rear direction by an actuator, a rectangular net 153, and a net support unit 154. The net support unit 154 is provided at the front ends of the column 152, 152 and supports both sides of the net 153. It comprises a support plate 154a that moves in accordance with the front-rear movement of the column 152, 152, and a top plate 154b that has a U-shape in plan view and is attached to the support plate 154a.

[0120] The body surface shape measuring device 14 can be used at an angle from 0 to 90 degrees relative to the horizontal. For example, if a user sleeps in a napping chair at an angle of 85 degrees from the horizontal, the body surface shape measuring device 14 is tilted to 85 degrees, and the body surface shape in the sleeping position is measured while the user is relaxed. The chair surface is then formed based on this body surface shape. This allows for a good night's sleep.

[0121] (Embodiment 7) The storage unit 122 of the PC 12 according to Embodiment 7 has the same configuration as the bedding manufacturing system 25 according to Embodiment 5, except that it stores the learning model described below and a database of training data for the learning model. The training data database stores first data relating to the body surface shape of a large number of users in a standing or sitting position, and second data obtained by the body surface shape measuring device 14 of Embodiment 4, relating to the same user in a lying position.

[0122] Figure 28 is a schematic diagram illustrating an example of a learning model. The learning model is intended for use as a program module, which is part of artificial intelligence software. It can utilize multi-layer neural networks (deep learning), such as a Convolutional Neural Network (CNN). Other machine learning methods may also be used. The control unit 121 operates according to commands from the learning model, performing calculations on the first data input to the input layer of the learning model, and outputting second data and probabilities related to the body surface shape of a human body in a sleeping position. In the case of a CNN, the hidden layers include convolution layers, pooling layers, and fully connected layers. The number of nodes (neurons) is not limited to the case shown in Figure 26.

[0123] The input layer, output layer, and hidden layer each contain one or more nodes, and the nodes in each layer are connected in one direction to the nodes in the preceding and succeeding layers with a desired weight.

[0124] The input layer of a trained model receives the first data. The data given to the nodes in the input layer is then input to the first hidden layer, where the output of the hidden layer is calculated using weights and activation functions. This calculated value is then passed to the next hidden layer, and so on, until the output of the output layer is obtained, and so on, until the output of the output layer is obtained. All the weights connecting the nodes are calculated by the training algorithm.

[0125] The output layer of the learning model outputs the second data point and its probability.

[0126] The control unit 121 uses training data to generate a learning model that outputs second data when first data is input. Specifically, the control unit 121 inputs training data into the input layer, performs calculations in the hidden layer, and then obtains second data from the output layer. The control unit 121 compares the second data output from the output layer with the second data labeled in the training data for the first data, i.e., the correct answer value, and optimizes the parameters used in the calculation processing in the hidden layer so that the output value from the output layer approaches the correct answer value. These parameters include, for example, the weights (coupling coefficients) and activation function coefficients mentioned above. The method of parameter optimization is not particularly limited, but for example, the control unit 121 optimizes various parameters using backpropagation. The control unit 121 stores the generated learning model in the storage unit 122 and terminates the series of processes.

[0127] The control unit 121 acquires first data relating to the body surface shape of the user in a standing or sitting position, which is captured using a camera or the like. The control unit 121 inputs the first data into the learning model. The control unit 121 acquires, for example, second data with a probability of 80% or higher, based on the second data and probability output by the learning model. According to this embodiment, the body surface shape of the user in a standing or sitting position can be easily measured, and the body surface shape in a lying position, which would be obtained when using the body surface shape measuring device 14, can be acquired without using the body surface shape measuring device 14.

[0128] (Embodiment 8) Figure 29 is a cross-sectional view showing a body surface shape measuring device 52 according to Embodiment 8. The body surface shape measuring device 52 comprises a rectangular plate portion (support base) 53, four column portions 54 that support the plate portion 53, and a molding material 55. The molding material 55 is placed on the plate portion 53. The molding material 55 plastically deforms under its own weight when the user lies on its back and has shape retention properties that maintain the deformed shape. Examples of materials for the molding material 55 include silicone rubber, clay, gel, jelly, and plaster. Alternatively, BAUERFEIND's impression foam "Trisham" may be used as the molding material 55. When using "Trisham," it is preferable to prepare several levels of hardness to match the weight of the user's head.

[0129] Figure 30 is a plan view showing the molding material 55 after molding. A recess 56 is formed that conforms to the shape of the user's body surface.

[0130] According to the above configuration, the recess 56 allows for the acquisition of data relating to the surface shape of the part of the body being measured while the human body is suspended in a sleeping position. The recess 56 allows for the direct acquisition of the shape of the recess or cut part that serves as a receptacle for the user's body in a mat or pillow, and also allows for the acquisition of height data of the block, enabling the easy and rapid manufacture of bedding.

[0131] (Embodiment 9) Figure 31 is a cross-sectional view showing a body surface shape measuring device 52 according to Embodiment 9. The body surface shape measuring device 52 comprises a rectangular plate portion 57, multiple sets of two or four column portions 58, 58 that support the plate portion 57, and a molding material 55. The multiple plate portions 57 are arranged side by side in the longitudinal direction of the human body. The column section 58 can be moved up and down by an actuator.

[0132] In this embodiment, a molding material 55 is placed on the part of the body surface to be measured. The height of the plate portion 57 on which the molding material 55 is placed, and the other plate portions 57 are adjusted so that the part is suspended in mid-air when the user is lying down. The height can also be adjusted to match the bedding the user is using.

[0133] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The technical features described in the embodiments can be combined with each other, and the scope of the present invention is intended to include all modifications within the claims and equivalents thereof.

[0134] The configuration of the pillow 1 and the mat 17 is not limited to the configuration described in the above embodiment. The pillow 1 is not limited to cases where it has contact portions 3, 4, and 5. For example, if the user mainly sleeps on their back, only one contact portion 3 may be provided in the center. Alternatively, three contact portions 3 may be provided, in which case the shape of the peripheral edges of the left and right through holes 31 may be changed in response to the user turning over in their sleep.

[0135] The body surface shape measuring device 14 is not limited to a case where the measuring unit 15 and the support unit 141 are separate; it may also be configured such that the measuring unit 15 is fitted into the head-side inner portion of the support unit 141. Furthermore, the user's sleeping posture may be recorded in advance as a video using motion capture or similar methods, and the shape of the contact parts 3, 4, and 5 may be determined based on the characteristics of their turning over during sleep. [Explanation of Symbols]

[0136] 1 pillow 2 Main unit 21, 23 Recess 22, 24 Through holes 3, 4, 5 Contact part 31, 41, 51 Through holes 6. Inner cover 7. Pipe housing section 8 Board part 9. Outer cover 10 Head Data 11 Acquisition device 12 PC 121 Control Unit 122 Storage section 123 Pillow Manufacturing Program 124 Input section 125 Interface section 126 Mat Manufacturing Program 13. Bedding Manufacturing System 14, 52 Body surface shape measuring device 141 Support part 15 Measuring part 150 Head measurement section 151, 164 units 152, 162, 54, 58 Column section 153, 156 Net 154, 163 Net support section 161 Information Department 53, 57 plate part 55 molding material 17 Matt 171, 172 recess 18, 19 Contact part 181, 191 Through holes

Claims

1. The bedding itself, Based on the suspended body surface shape of a human body in a sleeping position, the bedding body is provided with a plurality of recesses and protrusions, Multiple contact parts that are fitted into the aforementioned multiple recesses and come into contact with the part of the human body that bears the weight of the body in a sleeping position Bedding equipped with [specific features / features].

2. The bedding itself, Based on the surface shape of the human body in a suspended state while lying down, the bedding body has multiple cut sections, A contact portion made of synthetic resin is laminated on the part of the cutting section that is subjected to the weight of the human body, and the part comes into contact with the contact portion. Bedding equipped with [specific features / features].

3. A bedding set comprising multiple synthetic resin blocks arranged based on the surface shape of the human body in a suspended state while sleeping.

4. By acquiring data related to the surface shape of the body part being measured while the human body is suspended in a lying position, Based on the body surface shape, a plurality of recesses and protrusions are provided on the bedding body. A method for manufacturing bedding, comprising fitting a contact portion into the recess, the contact portion which contacts the part of the human body that bears weight.

5. By acquiring data related to the surface shape of the body part being measured while the human body is suspended in a lying position, Based on the aforementioned body surface shape, the bedding body is cut, A method for manufacturing bedding, comprising laminating synthetic resin onto the load-bearing portion of a cut-out section, thereby providing a contact portion that the load-bearing portion makes contact with.

6. The method for manufacturing bedding according to claim 5, wherein the synthetic resin is laminated in such a way that it does not collapse under its own weight and the amount applied to the load portion is controlled so as to represent the shape of the body surface.

7. By acquiring data related to the surface shape of the body part being measured while the human body is suspended in a lying position, A method for manufacturing bedding, comprising arranging multiple synthetic resin blocks of different materials, hardnesses, or heights based on the body surface shape.

8. A method for manufacturing bedding according to any one of claims 4 to 7, comprising taking a mold of the part to be measured and obtaining data relating to the surface shape of the part to be measured.

9. First data relating to the surface shape of the human body in a standing or sitting position is obtained. A method for manufacturing bedding according to any one of claims 4 to 8, wherein first data relating to the surface shape of the human body in a standing or sitting position and second data relating to the surface shape of the part of the human body to be measured in a suspended state in a lying position are used as training data, and the acquired first data is input to a learning model that outputs the second data when the first data is input to acquire the second data of the human body.

10. By acquiring data related to the surface shape of the body part being measured while the human body is suspended in a lying position, Based on the aforementioned body surface shape, the bedding body is cut, A synthetic resin is laminated onto the load-bearing portion of the machined area, creating a contact area that the load-bearing portion makes contact with. A computer program that instructs a computer to perform a process.

11. The pillow itself, It is made of a different material from the pillow body, is fitted into the pillow body, and has a contact portion that comes into contact with the head when sleeping. A pillow equipped with [a specific feature].

12. The pillow body has a recess that is open at the top, The pillow according to claim 11, wherein the contact portion is fitted into the recess.

13. The pillow according to claim 12, wherein the contact portion has a first through hole.

14. The aforementioned recess has a second through hole, The pillow according to claim 13, wherein the first through hole communicates with the second through hole.

15. A cylindrical portion that fits into the first through hole and the second through hole, The first cover covers the pillow body and The pillow according to claim 14, comprising:

16. The pillow according to any one of claims 13 to 15, wherein the curved shape of the peripheral edge of the first through hole of the contact portion has a shape corresponding to the bone shape of the head and the sleeping position.

17. An adjustment member for adjusting the height is located on the back side of the pillow body, The adjustment member and the second cover that covers the pillow body A pillow according to any one of claims 11 to 16, comprising:

18. The contact portion includes a three-layer structure consisting of a hard synthetic resin, a urethane resin, and a gel. The pillow according to any one of claims 11 to 17.

19. The aforementioned contact portion has three parts, depending on the sleeping position. The pillow according to any one of claims 11 to 18.

20. The aforementioned contact portion is detachable. The pillow according to any one of claims 11 to 19.

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