mattress

Abstract

To provide a mattress which has hard side parts, is prevented from being torn during maintenance, and is comfortable to use and easy for a user to turn over in bed. [Solution] A mattress consisting of a three-dimensional mesh structure made of random loops of continuous filaments made of thermoplastic resin and having partial welded portions of the loops, the mattress comprising, in the short direction of the mattress, a central portion, side hard portions formed on the left and right longitudinal sides and having a higher average bulk density than the central portion, and an intermediate hard portion located between the central portion and the side hard portions and having a higher average bulk density than the central portion and a lower average bulk density than the side hard portions, the width of the central portion being greater than the sum of the widths of the side hard portions and the intermediate hard portions.

Description

[Technical field]

[0001] The present invention relates to a mattress having a three-dimensional mesh structure. [Background technology]

[0002] 2. Description of the Related Art Conventionally, it is known that in a mattress made of a three-dimensional net-like structure, the left and right longitudinal sides are provided with hard side portions having a higher bulk density than the remaining portions.

[0003] Patent Document 1 discloses a condensation prevention mattress that is made by melting a thermoplastic resin, which is a raw material or a main raw material, and extruding it as filaments, and then forming an aggregate of the filaments into a substantially plate-like shape and cooling and solidifying the filaments, and that is characterized by having hard side portions with high bulk density on the left and right long sides. These hard side portions suppress deformation of the structure, improving breathability and contributing to preventing condensation.

[0004] Patent Document 2 discloses that, for the purpose of improving body pressure dispersion, a three-dimensional mesh structure is formed to be softer closer to the center line and harder toward the sides. The closer to the center of a person, the easier it is to sink, and the closer to the sides of the person, the harder it is to sink. The three-dimensional mesh structure 70 is less able to support a person's weight closer to the center line, and easier to support a person's weight toward the sides, improving the body pressure dispersion of the three-dimensional mesh structure. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2010-279687 A [Patent Document 2] JP 2006-97223 A Summary of the Invention [Problem to be solved by the invention]

[0006] The mattress made of the three-dimensional net structure described in Patent Document 1 is also used as a nursing mattress or a medical mattress because of its washable advantage. In this case, the mattress is periodically cleaned and other maintenance is performed, and the hard side portions are also used as a part for the worker to hold. However, during such maintenance or moving, or for example, when removing the mattress from the cover, the hard side portions have a problem that stress is concentrated at the boundary between the hard side portions and other portions, causing the fusion to come off and tear. In particular, if the center portion that supports the human body is made soft, the difference in bulk density between the hard side portions and the center portion becomes large, and the above problem becomes more likely to occur.

[0007] The three-dimensional net structure of Patent Document 2 has a problem in that when a person lies down, the undersides of the person's sides become hard, making it difficult for the person to turn over in bed.

[0008] Therefore, the object of the present invention is to provide a mattress that has hard side portions, is less likely to tear during maintenance, and is easy to turn over in and comfortable to use. [Means for solving the problem]

[0009] The present invention is a mattress consisting of a three-dimensional mesh structure made of random loops of continuous filaments made of thermoplastic resin and having partial welded portions of the loops, and in the short direction of the mattress, the mattress comprises a central portion, side hard portions formed on the left and right longitudinal sides and having a higher average bulk density than the central portion, and an intermediate hard portion located between the central portion and the side hard portions and having a higher average bulk density than the central portion and a lower average bulk density than the side hard portions, and the width of the central portion is greater than the sum of the widths of the side hard portions and the intermediate hard portions.

[0010] The difference between the average bulk density of the side hard portion and the average bulk density of the intermediate hard portion is preferably larger than the difference between the average bulk density of the intermediate hard portion and the average bulk density of the central portion.

[0011] The width of the intermediate hard portion is preferably greater than the width of the side hard portion.

[0012] The average bulk density of the hard side portions is preferably 2 to 3 times the average bulk density of the central portion.

[0013] It is preferred that the mattress comprises a first region located centrally in the longitudinal direction of the mattress and second regions located on either side of the first region and having a lower average bulk density than the first region. Effect of the Invention

[0014] According to the present invention, the middle hard portion is located between the side hard portions with high bulk density and the center portion with low bulk density, and the bulk density changes stepwise, so that the stress applied during transportation or maintenance is dispersed, and it is possible to provide a mattress that is less likely to tear. In addition, since the difference in bulk density between the center portion and the side hard portions can be made large, the center portion can be made softer as needed. Furthermore, the end portions including the side hard portions and the middle hard portion are widened, so that when the mattress is used as a nursing mattress or a medical mattress, the user can sit stably on the end portions. [Brief description of the drawings]

[0015] [Figure 1] 1A is a plan view and FIG. 1B is a front view of the mattress of this embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] A mattress 1 of the present embodiment will be described with reference to Fig. 1. Note that the embodiment described below is an example of the present invention, and the present invention is not limited to the following embodiment.

[0017] The mattress 1 is made of a three-dimensional net-like structure consisting of random loops of continuous filaments made of a thermoplastic resin, with the loops having partially welded portions.

[0018] Examples of thermoplastic resins that can be used as raw materials for the three-dimensional network structure include polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides such as nylon 66, polyvinyl chloride, polystyrene, copolymers and elastomers copolymerized based on the above resins, blends of the above resins, etc. Thermoplastic synthetic resins mixed with antibacterial agents, non-flammable materials, and flame retardants, as well as biodegradable plastics, can also be used.

[0019] 1, the mattress 1 has, in the short direction, a central portion (A1, A2) located in the center, side hard portions (C1, C2) located on the left and right longitudinal sides, and intermediate hard portions (B1, B2) located between the central portion (A1, A2) and the side hard portions (C1, C2). The average bulk density of the intermediate hard portions (B1, B2) is higher than that of the central portions (A1, A2), and the average bulk density of the side hard portions (C1, C2) is higher than that of the intermediate hard portions (B1, B2).

[0020] The difference between the average bulk density of the side hard parts (C1, C2) and the average bulk density of the middle hard parts (B1, B2) is larger than the difference between the average bulk density of the middle hard parts (B1, B2) and the average bulk density of the center parts (A1, A2). In other words, the middle hard parts (B1, B2) are hard parts, but are designed to have a bulk density close to that of the center parts (A1, A2) and not be too hard even when supporting a user who turns over in bed.

[0021] The average bulk density of the central part (A1, A2) is 10 to 80 kg / m 3 is preferable, and the average bulk density of the hard side parts (C1, C2) is 100 to 200 kg / m 3 is preferable, and the average bulk density of the intermediate hard part (B1, B2) is 30 to 100 kg / m 3 In this embodiment, the average bulk density of the right side hard portion (C1, C2) and the left side hard portion (C1, C2) is the same, but may be different. Similarly, the average bulk density of the right side middle hard portion (B1, B2) and the left side middle hard portion (B1, B2) is the same, but may be different.

[0022] The width of the center (a) is greater than the sum (2 x (b + c)) of the widths of the side hard parts (C1, C2) and the middle hard part (B1, B2). The width (b) of the middle hard part is also greater than the width (c) of the side hard part. This ensures a wide, soft area that is comfortable for the user when lying down, making it easier to turn over in bed.

[0023] In this embodiment, the presence of the intermediate hard parts (B1, B2) allows the bulk density to change stepwise, dispersing stress during transportation or maintenance, thereby reducing the possibility of the mattress 1 tearing at the boundary between the side hard parts and the central part. Furthermore, the difference in bulk density between the side hard parts (C1, C2) and the central part (A1, A2) can be increased, making it possible to use a soft material with low bulk density for the central part (A1, A2). For example, the bulk density of the side hard parts (C1, C2) can be two to three times that of the central part (A1, A2).

[0024] The mattress 1 is used, for example, as a nursing mattress or a medical mattress. In nursing mattresses or medical mattresses, a person receiving care may sit on the edge of the mattress while waiting. According to this embodiment, the presence of the intermediate hard portion (B1, B2) widens the area of ​​high bulk density at the edge, making it easier for the body of a person receiving care to be supported when sitting on the edge.

[0025] In this embodiment, as shown in Fig. 1, the mattress 1 has a first region (A1, B1, C1) located in the center in the longitudinal direction, and second regions (A2, B2, C2) on both sides of the first region and having a lower average bulk density than the first region. The center portion (A1) of the first region has a higher average bulk density than the center portion (A2) of the second region, the side hard portion (C1) of the first region has a higher average bulk density than the side hard portion (C2) of the second region, and the middle hard portion (B1) of the first region has a higher average bulk density than the middle hard portion (B2) of the second region. This increases the durability of the center portion, which is more likely to receive load when sleeping or sitting on the mat and is frequently sat on when transferring.

[0026] The filaments constituting the mattress 1 may be solid, hollow, or irregular in cross section, and the diameter of the filaments is preferably 0.3 to 3.0 mm in the case of solid filaments, and preferably 0.2 to 5.0 mm in the case of irregular or hollow filaments. The diameter is determined by cutting out a resin thread from the center of the sample, measuring the thickness of the resin thread five times with a caliper, and averaging the measured values. In this embodiment, the center portion is made of filaments with a diameter of 0.5 to 1.6 mm, and the side hard portion and the middle hard portion are formed by mixing filaments with a diameter of 0.5 to 1.6 mm and filaments with a diameter of 1.6 to 2.6 mm.

[0027] The mattress 1 is used in a cover. The mattress 1 may be a single piece, but may also be split into multiple pieces (for example, into three pieces) in the longitudinal direction for ease of transportation and storage. In that case, the split pieces may be housed in an inner cover and the covers may be joined together. Also, the mattress 1 may have cuts at the bending parts to make it easier to fold. Also, a sheet made of urethane foam and / or a nonwoven sheet or solid cotton may be layered on the upper or lower side of the mattress 1.

[0028] The mattress 1 may further have dense parts with relatively high bulk density and sparse parts with relatively low bulk density in the thickness direction. For example, there may be surface layers that are dense parts on the upper and lower surfaces and a sparse part in the center, or one of the upper and lower surfaces may be a dense part and the other a sparse part in order to change the softness between the front and back.

[0029] In this embodiment, only the central part, the side hard parts, and the intermediate hard part exist in the short direction, but for example, a second intermediate hard part may further exist between the intermediate hard parts (B1, B2) and the central parts (A1, A2). In that case, it is preferable that the second intermediate hard part has an average bulk density lower than that of the intermediate hard parts (B1, B2) and higher than that of the central parts (A1, A2).

[0030] In order to accommodate tracking ability, etc., a sparse or dense structure may exist in the longitudinal or lateral directions within the central portion (A1, A2), the lateral hard portions (C1, C2), the intermediate hard portions (B1, B2), and within the first portion (A1, B1, C1) and the second portion (A2, B2, C2).

[0031] Next, the manufacturing method of the three-dimensional netted structure used in the present invention will be described below. For details, please refer to the applicant's publications such as Japanese Patent No. 4350286, US Patent No. 7,625,629, and International Publication No. WO2012 / 157289.

[0032] The raw materials are melted at a melting temperature 10 to 20 degrees Celsius higher than their melting point. The molten raw materials are sent into the die, where pressure is applied. Each filament is discharged from the extrusion port of the lower die. Due to the arrangement of multiple extrusion holes, the filament aggregate is made up of multiple filaments and falls naturally.

[0033] The temperature inside the die can be set to a range of 100 to 400° C., more preferably 120 to 350° C., and the extrusion rate can be set to a range of 20 to 200 kg / hr, etc. The pressure inside the die can be, for example, the discharge pressure of a 75 mm screw, and the pressure range is about 0.2 to 25 MPa.

[0034] The diameter of the extrusion nozzle of the die corresponds to the diameter of the filaments of the structure, and is preferably 0.1 to 5.0 mm, more preferably 0.5 to 3.0 mm. The bulk density can be adjusted by changing the hole diameter of the extrusion nozzle or the distance between the extrusion nozzles.

[0035] Next, the filaments are caught by a pair of shooters, one on the left and one on the right, which are supplied with water or hot water, and are brought into contact with each other in a molten state to fuse together, forming a three-dimensional structure, and are then dropped onto the water surface. At this time, the loop diameter and the filament diameter are determined by the angle of the shooters, the amount of water supplied, the diameter of the extrusion nozzle, the distance between the nozzle face, the shooters, and the take-up conveyor, the melt viscosity of the resin, the diameter of the extrusion nozzle hole, the discharge amount, etc.

[0036] Among the wire assembly, the wires located on the long side of the outer periphery come into contact with the inclined surface on which the water of the pair of long shooters is flowing, which disrupts the vertical descent trajectory, and while entangling with the adjacent wires in a loop, they slide down the inclined surface while being carried by the water or heated water supplied from the supply pipe. At this time, the wires are influenced by gravity and entangle along the inclined surface, forming a loop. A pair of short shooters may be provided, or a one-piece shooter may be provided. Shooters are not necessarily required.

[0037] Among the filament aggregate, those that descend without coming into contact with any of the inclined surfaces of the shooter pass through the forming opening of the shooter. At this time, among the filaments that pass through the forming opening, those that pass near the lower edge of the inclined surface come into contact with the filaments sliding down the inclined surface and become entangled in a loop shape, and the disturbance of the descending trajectory caused by the contact and entanglement spreads to a small extent to the adjacent filaments toward the center as they descend. Among the filaments that pass through the forming opening, those that pass near the center of the forming opening land on the water surface, and because the take-up speed of the take-up machine described below is slower than the descending speed of the filament aggregate, each of the filaments that land on the water bends and becomes entangled in a roughly loop shape near the water surface.

[0038] The three-dimensional network structure is cooled in a water tank, and is taken up and lowered by a pair of take-up machines at a speed slower than the descent of the assembly, and is clamped and transported.

[0039] <Example 1> Next, a first embodiment will be described. The mattress is made of polyester elastomer resin and has a three-dimensional net structure with a width of 900 mm, a length of 1920 mm, and a thickness of 50 mm. The average bulk density of A1 is 60 kg / m 3 , the average bulk density of A2 is 55kg / m 3 , the average bulk density of B1 is 72 kg / m 3 , the average bulk density of B2 is 66 kg / m 3 , the average bulk density of C1 is 130 kg / m 3 , the average bulk density of C2 is 120 kg / m 3The width a of the central portion (A1, A2) is 500 mm, the width c of the side hard portions (C1, C2) is 80 mm, and the width b of the intermediate hard portions (B1, B2) is 120 mm. The length L1 of the first portions (A1, B1, C1) is 640 mm, and the length L2 of each of the second portions (A2, B2, C2) is 640 mm.

[0040] In the mattress formed in the embodiment, when stress is applied, the stress is dispersed and tearing is suppressed, compared to a mattress without an intermediate hard portion.

[0041] The present invention is not limited to the above-described embodiments, and various modifications, substitutions, deletions, etc. can be made without departing from the technical idea of ​​the present invention, and modifications, equivalents, substitutions, deletions, etc. are also included in the technical scope of the present invention. [Explanation of symbols]

[0042] 1: Mattress A1, A2: Central part B1, B2: Intermediate hard part C1, C2: Side hard part

Claims

1. A mattress comprising a three-dimensional net structure made of random loops of continuous filaments made of a thermoplastic resin and having partial welded portions of the loops, In the short direction of the mattress, The center and A side hard portion formed on each of the left and right longitudinal sides and having an average bulk density higher than that of the central portion; An intermediate hard portion is located between the central portion and the side hard portion, and has an average bulk density higher than that of the central portion and lower than that of the side hard portion. The width of the central portion is greater than the sum of the widths of the side hard portion and the intermediate hard portion. mattress.

2. The difference between the average bulk density of the side hard portion and the average bulk density of the intermediate hard portion is The difference between the average bulk density of the intermediate hard portion and the average bulk density of the central portion is greater than the difference between the average bulk density of the intermediate hard portion and the average bulk density of the central portion.

2. The mattress of claim 1.

3. The width of the intermediate hard portion is greater than the width of the side hard portion.

2. The mattress of claim 1.

4. The average bulk density of the side hard portion is 2 to 3 times the average bulk density of the central portion.

2. The mattress of claim 1.

5. In the longitudinal direction of the mattress, A first portion located at a center; a second section on each side of the first section and having a lower average bulk density than the first section; 2. The mattress of claim 1.

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