mattress

Abstract

Prevents deterioration of sleeping comfort due to sagging of the mattress. [Solution] This mattress has solid cotton 2 as a core material and layered cotton 4 laminated thereon, and is equipped with a buttocks section B where the sleeper's buttocks come into contact, a head section A closer to the sleeper's head than that, and a foot section C closer to the sleeper's feet than the buttocks section B. Extra cotton 8 is laminated on the solid cotton 2 and layered cotton 4 in the head section A, and by forming a layer of solid cotton 2, a layer of layered cotton 4, and a layer of extra cotton 8 in the head section A, the thickness of the head section A is made thicker than the buttocks section B and the foot section C.

Description

[Technical Field]

[0001] This invention relates to a mattress generally used for sleeping, and more particularly to a mattress having a solid cotton core and a layer of cotton layered on top of it. [Background technology]

[0002] Futon mattresses are made by stacking layers of cotton of a certain thickness as the filling, covering this with a side cloth, and sewing it together with threads that run from top to bottom. The cotton is compressed and deformed during use by the weight of the sleeper, but for a certain period after the initial use, when the sleeper wakes up, the cotton's elasticity and other properties allow it to recover its shape and the deformation of the mattress is restored.

[0003] However, when a mattress is used for a long period of time, the weight of the sleeper is repeatedly applied to it, which reduces the ability of the cotton to recover its shape, causing the mattress to gradually become worn out. This wear increases over time, resulting in a problem of poor comfort.

[0004] To improve this, some products have a flat mat-like structure or a foam sheet with an uneven surface that is sandwiched between the upper and lower layers of cotton. Another product uses a hollow net structure as the core, with the upper and lower surfaces woven with fiber threads to create a honeycomb-like flat surface, and the upper and lower surfaces are connected by numerous connecting threads in the vertical direction (Patent Document 1). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-6970 Summary of the Invention [Problem to be solved by the invention]

[0006] However, while these conventional mattresses are constructed uniformly along their entire length, the weight of the sleeper is not distributed evenly along the entire length of the mattress, so the parts of the mattress that bear the greater weight tend to wear out. For this reason, conventional mattresses have not been able to fully solve this problem of wear and tear. The inventor of this invention noticed that while sagging of a mattress can occur in the core material, it is more likely to occur in the cotton layers, such as those placed on the surface or front and back of the core material.

[0007] The parts of the mattress that are most susceptible to sagging due to the heavy weight of the sleeper are the buttocks part where the sleeper's buttocks come into contact and the head part closer to the sleeper's head. Of these two parts, sagging in the head part in particular has the greatest impact on the deterioration of sleeping comfort, and this invention was based on the inventor's knowledge. Therefore, this invention aims to prevent the deterioration of sleeping comfort due to the mattress becoming worn out. [Means for solving the problem]

[0008] In order to solve the above problems, one embodiment of this invention is a mattress that has solid cotton as a core material and layered cotton laminated on top of it, and when this mattress is divided into a buttocks portion where the sleeper's buttocks rest, a head portion that is closer to the sleeper's head than that, and a foot portion that is closer to the sleeper's feet than the buttocks portion, by adding a layer of extra cotton to the solid cotton and layered cotton in the head portion, the thickness of the head portion is made thicker than the buttocks and foot portions.

[0009] The solid cotton in the buttocks portion may be harder than the solid cotton in the head and foot portions. Alternatively, the thickness of the foot-side portion can be made thinner than the buttocks portion by layering the layer of cotton over the entire upper surface of the solid cotton, and layering cotton over the head and buttocks portions of the lower surface of the solid cotton, excluding the foot-side portion. Here, the layer of cotton over the upper surface of the solid cotton and the layer of cotton under the solid cotton may be separate, or may be continuous as described below.

[0010] Furthermore, the extra cotton may be interposed between the solid cotton and the overlying cotton above it, and the overlying cotton may be continued below the solid cotton by wrapping the tips of the head portions of the extra cotton and the solid cotton from above the extra cotton. Here, the meaning of continuing the overlying cotton from above the extra cotton to below the solid cotton does not mean that the overlying cotton is wrapped from above the extra cotton to below the solid cotton, but rather that the overlying cotton is continuous. Therefore, it goes without saying that the overlying cotton may be wrapped from top to bottom, or vice versa. [Effects of the Invention]

[0011] According to this invention, by making the thickness of the head side, which has the greatest impact on the deterioration of sleeping comfort, thicker than the buttocks and foot side, it is possible to suppress the sagging of the head side, and prevent the deterioration of sleeping comfort due to the sagging of the mattress. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 shows the first embodiment of the present invention, and is an explanatory diagram showing the positions of the sleeper and the mattress. [Figure 2] FIG. 2 is an explanatory diagram illustrating the structure of the mattress of FIG. 1 in an emphasized manner. [Figure 3] FIG. 10 is an explanatory diagram similar to FIG. 2, showing a second embodiment of the present invention. [Figure 4] FIG. 10 is an explanatory diagram similar to FIG. 2, showing a third embodiment of the present invention. [Figure 5] FIG. 10 is an explanatory diagram similar to FIG. 2, showing a fourth embodiment of the present invention. [Figure 6] FIG. 10 is an explanatory diagram similar to FIG. 2, showing a fifth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0013] Next, first to fourth embodiments of the present invention will be described. "First embodiment" 1 and 2 show the first embodiment, and Fig. 1 is a schematic diagram explaining the position of a sleeper P and a cross-sectional view of a mattress 1. Fig. 2 is an explanatory diagram showing a cross-sectional view of the mattress 1 in Fig. 1, further emphasizing the structure of the mattress 1.

[0014] Here, the mattress 1 is divided into a buttocks portion B where the buttocks of the sleeper P come into contact, a head portion A closer to the head of the sleeper P than the buttocks portion B, and a foot portion C closer to the feet of the sleeper P than the buttocks portion B. In this embodiment, each of portions A, B, and C constitutes about one-third of the length of the mattress 1 (in the direction of the height of the sleeper P), but the proportions of portions A, B, and C can be changed within a range that conforms to these definitions.

[0015] The mattress 1 also comprises solid cotton 2 as a core material, layered cotton 4 on top of this, and additional cotton 8 only in the head portion A, and the entire structure is covered with a side cloth 6 and sewn together with sewing thread not shown. The solid cotton 2 is formed as a single unit, but is divided into a head portion 2a located in the head portion A of the mattress 1, a butt portion 2b located in the butt portion B of the mattress 1, and a foot portion 2c located in the foot portion C of the mattress 1. The head portion 2a, butt portion 2b, and foot portion 2c of the solid cotton 2 are all continuous and have the same thickness, but in this embodiment, the butt portion 2b is formed harder than the head portion 2a and the foot portion 2c.

[0016] The solid batting 2 is formed by layering multiple sheets made of polyester cotton-like fibers and compressing them under heat to a uniform thickness. The number of sheets layered in the buttocks portion 2 is greater than that in the head-side portion 2a and foot-side portion 2c, and the entire solid batting 2 is heated and compressed to a uniform thickness. The aforementioned firmness is achieved by making the fiber density of the buttocks portion 2b higher than that of the head-side portion 2a and foot-side portion 2c. The firmness of the head-side portion 2a and foot-side portion 2c of the solid batting 2 is also the same. Of course, other well-known materials can be used for the solid batting 2. As mentioned above, the solid batting 2 is made of cotton-like fibers and is therefore cotton in a broad sense. However, because it is compressed and molded as mentioned above, it is firmer overall than the layered batting 4 and forms the core material of the mattress 1.

[0017] The layered batting 4 is made of a well-known or commonly used material and is of the same thickness throughout. This layered batting 4 is layered in the length and width directions of the mattress 1 so as to cover the entire upper surface of the solid batting 2. The layered batting 4 is layered continuously across the entire width direction of the mattress 1 so as to cover the underside of the head portion 2a and the butt portion 2b of the solid batting 2. However, it is not layered on the underside of the foot portion 2c of the solid batting 2.

[0018] The extra batting 8 is interposed between the top surface of the head portion 2a of the solid batting 2 and the overlay batting 4 above it in the head portion A of the mattress 1. This extra batting 8 is made of cotton of the same material and thickness as the overlay batting 4, and during the manufacturing process of the mattress 1, a portion of the material for the overlay batting 4 is previously cut to approximately the length of the head portion 2a of the solid batting 2. During the manufacturing process of the mattress 1, the extra batting 8 is layered on the top surface of the head portion 2a of the solid batting 2, and the long overlay batting 4 is then wrapped from the top surface of the foot portion 2c of the solid batting 2, over the top surface of the butt portion 2b, and over the top surface of the extra batting 8, and then under the bottom surface of the head portion 2a of the solid batting 2, and then disposed on the butt portion 2b of the solid batting 2. Here, an example is shown in which the overlay batting 4 is wrapped sequentially from the top to the bottom of the solid batting 2, but the overlay batting 4 may also be wrapped in the reverse order, from the bottom to the top of the solid batting 2.

[0019] Incidentally, the dimensions of the mattress 1 here are, for example, 200 cm in length and 100 cm in width. The solid batting 2 used in this case is 195 cm in length and 95 cm in width. The length and width of the solid batting 2 are slightly shorter than those of the mattress 1 because the edges of the overlapping batting 2 cover the periphery of the solid batting 2. Therefore, the solid batting 2 is essentially distributed over the entire length and width of the mattress 1.

[0020] In addition, with regard to the additional cotton 8, in relation to the fact that the layered cotton 4 is not layered on the underside of the foot side portion 2c of the solid cotton 2 as described above, it can be seen that in this embodiment, part of the layered cotton 4, which was previously on the underside of the foot side portion 2c of the solid cotton 2, has been moved from the underside of the foot side portion 2c of the solid cotton 2 to the upper surface of the head side portion 2a to form the additional cotton 8.

[0021] Thus, in the first embodiment, the head side portion A of the mattress 1 is made up of four layers across its entire width: two layers of overlapping cotton 4, the head side portion 2a of solid cotton 2, and the extra cotton 8. The buttocks portion B is made up of three layers across its entire width: two layers of overlapping cotton 4 and the buttocks portion 2b of solid cotton 2. The foot side portion C is made up of two layers across its entire width: one layer of overlapping cotton 4 and the foot side portion 2c of solid cotton 2, so that the thickness of the mattress 1 is greatest at the head side portion A, gradually decreasing towards the foot side, and is thinnest at the foot side portion C.

[0022] In the first embodiment, the thickness of the mattress 1 is expressed as large, medium, and small, with the head portion A being large, the butt portion B being medium, and the foot portion C being small. Therefore, even if the layered cotton 4 and extra cotton 8 in the head portion A are compressed and deformed to some extent with long-term use, the thickness of the head portion A is prevented from becoming smaller than the thickness of the butt portion B, which has the effect of suppressing sagging of the head portion A, which has the greatest influence on the deterioration of sleeping comfort (first effect).

[0023] In addition, in the first embodiment, the buttocks portion 2b of the solid cotton 2 is made harder than the head-side portion 2a and the foot-side portion c of the solid cotton 2, so the buttocks portion B of the mattress 1 is made harder than the other portions A and C. This prevents the buttocks portion B, which is prone to compressive deformation under the weight of the sleeper P, from becoming worn down, which has the effect of making it easier to turn over while sleeping (second effect).

[0024] Furthermore, in the first embodiment, the foot side portion C of the mattress 1 is made up of two layers: one layer of extra cotton 4 and the foot side portion 2c of solid cotton 2, making it thinner than the buttocks portion B. As a result, one layer of extra cotton 4 can be omitted in the foot side portion C, and the amount of cotton used can be offset by the additional extra cotton 8. This prevents an increase in material costs. Furthermore, since the foot side portion C is not subjected to a large load while sleeping, there is no risk of sagging in this portion (third effect).

[0025] Furthermore, in the first embodiment, the extra padding 8 is interposed between the solid padding 2 and the overlay padding 4 above it, and the overlay padding 4 is wrapped around the tips of the head-side portions of the extra padding 8 and the solid padding 2 from above the extra padding 8, and is continuous below the solid padding 2. As a result, the sleeper P only comes into contact with the overlay padding 4 through the side cloth 6, and even if there is some unevenness or turning up at the end of the extra padding 8 (i.e., the end near the buttocks part B of the mattress 1), the sleeper P will not feel uncomfortable, and there is also the effect of being able to provide a natural sleeping comfort (fourth effect).

[0026] In the first embodiment, the layered batting 4 is disposed on both the upper and lower surfaces of the solid batting 2, but may be disposed only on the upper surface of the solid batting 2.

[0027] Furthermore, in this embodiment, the layered cotton 4 is a single piece of cotton that is integrally arranged continuously on both the top and bottom surfaces of the solid cotton 2, but even when layered cotton 4 is arranged on the top and bottom surfaces of the solid cotton 2, the layered cotton 4 on the top and bottom surfaces of the solid cotton 2 may not be integral but may be separate.

[0028] "Second embodiment" FIG. 3 shows a second embodiment, and is an explanatory diagram showing a cross section of the mattress 1 in the same manner as that shown in FIG.

[0029] In this embodiment, the extra batting 8 in the head-side portion A of the mattress 1 is layered on top of the extra batting 4. That is, the long extra batting 4 is wound from the top of the foot-side portion 2c of the solid batting 2, over the top of the buttocks portion 2b and the top of the head-side portion 2a, in that order, past the head-side end of the solid batting 2, and onto the bottom of the head-side portion 2a, and then onto the buttocks portion 2b of the solid batting 2. Note that the procedure for arranging this extra batting 4 may also be reversed, wrapping from the bottom to the top of the solid batting 2, as in the first embodiment.

[0030] In this way, the layered cotton 4 is arranged on the upper and lower surfaces of the solid cotton 2 except for the foot side portion 1c of the solid cotton 2, and then the extra cotton 8 is layered on the upper surface of the layered cotton 4 in the head side portion A of the mattress 1 so as to sandwich the layered cotton 4 between the head side portion 2a of the solid cotton 2.

[0031] Here, the only difference is the position of the layer of extra cotton 8, and the rest is the same as in the first embodiment, so the same reference numerals as in the first embodiment are used and redundant explanations will be omitted. In the second embodiment, the first, second, and third effects of the first embodiment described in the first embodiment are all achieved.

[0032] "Third embodiment" FIG. 4 shows a third embodiment, and is an explanatory diagram showing a cross section of the mattress 1 in a schematic manner similar to that shown in FIGS.

[0033] In this embodiment, the overlay 4 is placed over the entire upper and lower surfaces of the solid batting 2. That is, in the first and second embodiments shown in Figures 1 to 3, the overlay 4 is not layered on the underside of the foot side portion 2c of the solid batting 2, but in this embodiment, the overlay 4 is layered on the underside of the foot side portion 2c of the solid batting 2, continuing from the buttocks portion 2b. As a result, the thickness of the head side portion A of the mattress 1 is greater than the buttocks portion B, as in the first and second embodiments, but the thickness of the foot side portion C is the same as the thickness of the buttocks portion B.

[0034] Here, the only difference is that the layered cotton 4 is layered continuously from the buttocks portion 2b on the underside of the foot side portion 2c of the solid cotton 2, and otherwise it is the same as the first embodiment, so the same symbols as in the first embodiment will be used and redundant explanations will be omitted.

[0035] This third embodiment achieves the first, second, and fourth effects of the first embodiment described in the first embodiment. In addition, since the foot portion C of the mattress 1 is the same thickness as the buttock portion B, this is the same as conventional mattresses and there is no possibility of feeling uncomfortable (fifth effect).

[0036] "Fourth embodiment" FIG. 5 shows a fourth embodiment, and is an explanatory diagram showing a schematic cross section of a mattress 1 similar to those shown in FIGS.

[0037] In this embodiment, the solid batting 2 differs from the other embodiments. That is, in the first to third embodiments shown in Figures 1 to 4, the buttocks portion 2b of the solid batting 2 is formed to be harder than the other head-side portion 2a and foot-side portion 2c, but in this fourth embodiment, the solid batting 2 is formed so that the head-side portion 2a, buttocks portion 2b, and foot-side portion 2c are all uniformly hard.

[0038] Here, the only difference is that the entire solid cotton 2 from the head side portion 2a to the foot side portion 2c is molded to the same hardness, and otherwise it is the same as the first embodiment, so the same symbols as in the first embodiment will be used and redundant explanations will be omitted. In the fourth embodiment, the first, third, and fourth effects of the first embodiment described in the first embodiment are all achieved.

[0039] "Fifth embodiment" FIG. 6 shows a fifth embodiment, and is an explanatory diagram showing a schematic cross section of a mattress 1 similar to those shown in FIGS.

[0040] In this embodiment, the layered cotton 4 is layered continuously from the buttocks portion 2b onto the underside of the foot side portion 2c of the solid cotton 2, as in the third embodiment shown in Fig. 4. Therefore, the thickness of the head side portion A of the mattress 1 is greater than the buttocks portion B, as in the first, second, third and fourth embodiments, but the thickness of the foot side portion C is the same as the thickness of the buttocks portion B, as in the third embodiment shown in Fig. 4.

[0041] Here, the same as in the third embodiment, the layered batting 4 is layered continuously from the hip portion 2b on the underside of the foot side portion 2c of the solid batting 2. Also, the same as in the fourth embodiment, the solid batting 2 is molded to a uniform hardness in its continuous head side portion 2a, hip portion 2b, and foot side portion 2c. Since the other configurations are the same as in the first embodiment, the same reference numerals as in the first embodiment are used and redundant explanations will be omitted.

[0042] Therefore, the fifth embodiment achieves both the first effect of the first embodiment described in the first embodiment and the fifth effect described in the third embodiment.

[0043] "others" The first to fifth embodiments have been described above, and the relationship between these and claims 1 to 5 will be explained as follows.

[0044] First, the embodiment of the invention of claim 1 corresponds to the first to fifth embodiments (Figs. 1 to 6), the embodiment of the invention of claim 2 corresponds to the first to third embodiments (Figs. 1 to 4), the embodiment of the invention of claim 3 corresponds to the first, second, and fourth embodiments (Figs. 1, 2, 3, and 5), the embodiment of the invention of claim 4 corresponds to the first and second embodiments (Figs. 1 to 3), and the embodiment of the invention of claim 5 corresponds to the first embodiment (Figs. 1 and 2).

[0045] Furthermore, in these embodiments, a mattress 1 having a layer of solid cotton 2 and a layer of layered cotton 4 has been described, but of course, mattresses having additional layers in addition to these layers are also included in this invention. [Explanation of symbols]

[0046] P Sleeper A cranial part B. Buttocks C Foot side part 1 futon 2 hard cotton 2a Head part 2b Buttocks 2c Foot side part 4 Layered cotton 6 side cloth 8 Extra cotton

Claims

1. A mattress having solid cotton as a core material and layered cotton laminated thereon, when this mattress is divided into a buttocks portion where the buttocks of the sleeper come into contact, a head side portion closer to the head of the sleeper than the buttocks portion, and a foot side portion closer to the feet of the sleeper than the buttocks portion, The mattress is characterized in that the thickness of the head side part is made thicker than that of the buttocks part and the foot side part by adding a layer of extra cotton to the solid cotton and the layered cotton of the head side part.

2. A mattress having solid cotton as a core material and layered cotton laminated thereon, when this mattress is divided into a buttocks portion where the buttocks of the sleeper come into contact, a head side portion closer to the head of the sleeper than the buttocks portion, and a foot side portion closer to the feet of the sleeper than the buttocks portion, By adding a layer of extra cotton to the solid cotton and layered cotton of the head side portion, the thickness of the head side portion is made thicker than the buttocks part and the foot side portion, This mattress is characterized in that the solid cotton in the buttocks portion is harder than the solid cotton in the head and foot portions.

3. A mattress having solid cotton as a core material and layered cotton laminated thereon, when this mattress is divided into a buttocks portion where the buttocks of the sleeper come into contact, a head side portion closer to the head of the sleeper than the buttocks portion, and a foot side portion closer to the feet of the sleeper than the buttocks portion, By adding a layer of extra cotton to the solid cotton and layered cotton of the head side portion, the thickness of the head side portion is made thicker than the buttocks part and the foot side portion, This mattress is characterized in that the thickness of the foot side part is made thinner than the butt part by laminating overlapping cotton on the entire upper surface of the solid cotton, and also laminating overlapping cotton on the head side part and butt part of the lower surface of the solid cotton except the foot side part.

4. A mattress having solid cotton as a core material and layered cotton laminated thereon, when this mattress is divided into a buttocks portion where the buttocks of the sleeper come into contact, a head side portion closer to the head of the sleeper than the buttocks portion, and a foot side portion closer to the feet of the sleeper than the buttocks portion, By adding a layer of extra cotton to the solid cotton and layered cotton of the head side portion, the thickness of the head side portion is made thicker than the buttocks part and the foot side portion, The solid cotton in the buttocks portion is harder than the solid cotton in the head and foot portions, Furthermore, the mattress is characterized in that the thickness of the foot side part is made thinner than the butt part by laminating overlapping cotton on the entire upper surface of the solid cotton, and also laminating overlapping cotton on the head side part and butt part of the lower surface of the solid cotton except for the foot side part.

5. A mattress having solid cotton as a core material and layered cotton laminated thereon, when this mattress is divided into a buttocks portion where the buttocks of the sleeper come into contact, a head side portion closer to the head of the sleeper than the buttocks portion, and a foot side portion closer to the feet of the sleeper than the buttocks portion, By adding a layer of extra cotton to the solid cotton and layered cotton of the head side portion, the thickness of the head side portion is made thicker than the buttocks part and the foot side portion, The solid cotton in the buttocks portion is harder than the solid cotton in the head and foot portions, The upper surface of the solid cotton is entirely layered with overlapping cotton, and the lower surface of the solid cotton is also layered with overlapping cotton on the head and buttocks except for the foot side portion, so that the thickness of the foot side portion is thinner than that of the buttocks portion. Furthermore, the mattress is characterized in that the additional cotton is interposed between the solid cotton and the layered cotton on top of it, and the layered cotton is wrapped around the tip of the head side part of the additional cotton and the solid cotton from above the additional cotton and made continuous to the underside of the solid cotton.

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