mattress

Abstract

To provide a mattress where both end parts in a width direction are harder than a center part and which has excellent drying property when washed.SOLUTION: There is provided a mattress 10 where a first polyurethane foam 21 and a second polyurethane foam 31 harder than the first polyurethane foam 21 are lamination-bonded by holding an adhesive layer 25 between them. Third polyurethane foams 41 which are harder than the second polyurethane foam 31 and where ventilation in compliance with ASTM D7574 is equal to or more than 70 l / min are arranged in both end parts of the mattress 10 in a width direction W and held between at least one of the first polyurethane foam 21 and the second polyurethane foam 31 and the adhesive layer 25.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a mattress in which both widthwise ends are harder than the center and which has good washability and drying properties. [Background technology]

[0002] Nursing care mattresses can be subject to significant elastic deformation when the user or caregiver sits or leans against either end of the mattress in the width direction, resulting in an unstable posture and the risk of falling, or the loss of posture can make it difficult to provide care. To address this issue, the width ends of the mattress are made harder than the center.

[0003] A conventional mattress with hardened widthwise ends has a three-layer structure in which a surface layer, a middle layer, and a back layer are bonded together, and the middle layer is made of hard polyurethane foam members at both widthwise ends and a soft polyurethane foam member in the center (Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 4881667 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in conventional mattresses with a three-layer structure in which both widthwise ends are hardened, the hard polyurethane foam members that make up both widthwise ends of the middle layer are about 30 mm thick and are bonded with adhesive to the soft member in the center and the upper and lower surface and back layers.As a result, the sides and upper and lower surfaces of the soft member in the center widthwise are surrounded by a layer of adhesive that connects it to the hard members on both sides widthwise and the upper and lower surface and back layers.This means that if cleaning water gets into the center when the mattress is washed, it is difficult for it to evaporate to the outside, and it takes a long time to dry.

[0006] The present invention has been made in view of the above points, and has as its object to provide a mattress in which both widthwise ends are harder than the central portion and which dries easily when washed. [Means for solving the problem]

[0007] The invention of claim 1 is a mattress in which a first polyurethane foam and a second polyurethane foam having a hardness higher than that of the first polyurethane foam are laminated and bonded together with an adhesive layer sandwiched therebetween, the first polyurethane foam having a hardness higher than that of the second polyurethane foam and conforming to ASTM D 3 574, a third polyurethane foam having an air permeability of 70 l / min or more is provided at both ends of the width of the mattress, sandwiched between either the first polyurethane foam or the second polyurethane foam and the adhesive layer.

[0008] The invention of claim 2 is characterized in that, in claim 1, the third polyurethane foam has an elongation of 70% or more in accordance with JIS K6400-5.

[0009] The invention of claim 3 is characterized in that in claim 1 or 2, the third polyurethane foam has a thickness of 1 mm to 10 mm.

[0010] The invention of claim 4 is characterized in that, in any one of claims 1 to 3, the third polyurethane foam is positioned away from the widthwise and lengthwise ends of the mattress.

[0011] The invention of claim 5 is characterized in that, in any one of claims 1 to 4, the surface of at least one of the first polyurethane foam or the second polyurethane foam is provided with unevenness by profile processing.

[0012] The invention of claim 6 is characterized in that, in claim 5, the profiled surface area is two to four times larger than the flat surface when not profiled.

[0013] The invention of claim 7 is characterized in that in claim 5 or 6, the convex portion formed by the profile processing has a wedge-shaped cross section with a thickness smaller on the top side than on the base side. [Effects of the Invention]

[0014] The mattress of the present invention has a third polyurethane foam at both widthwise ends that is harder than the first and second polyurethane foams. Therefore, when a mattress user or caregiver sits or leans against both widthwise ends of the mattress, the mattress does not undergo large elastic deformation, preventing posture instability and supporting caregiving tasks.

[0015] In addition, in the mattress of the present invention, the surface of the third polyurethane foam provided at both ends in the width direction is covered with an adhesive layer on the surface that comes into contact with either the first polyurethane foam or the second polyurethane foam, and the other surface is not covered with an adhesive layer. 3 It has high breathability, with an air permeability of 70 l / min or more in accordance with JIS No. 574. Therefore, when the mattress is washed, the wash water that gets into the center of the mattress can evaporate to the outside through the highly breathable third polyurethane foam when the mattress is dried, resulting in good drying properties.

[0016] In the present invention, by making the third polyurethane foam have an elongation of 70% or more in accordance with JIS K6400-5, even if both widthwise ends of the mattress are pressed by nursing care work or the like and the third polyurethane foam at both widthwise ends is stretched and deformed, the third polyurethane foam is less likely to break.

[0017] In the present invention, by making the thickness of the third polyurethane foam as thin as 1 mm to 10 mm, the mattress can have a structure close to two layers, and the adhesive area of ​​the adhesive layer can be reduced, thereby further improving the drying properties of the mattress when washed.

[0018] In the present invention, by providing unevenness to the surface of at least one of the first polyurethane foam or the second polyurethane foam through profile processing, the surface area of ​​the mattress surface is increased, thereby improving the mattress's ease of cleaning and drying and its body pressure distribution.

[0019] By making the profiled surface area two to four times larger than the flat surface without profiling, the mattress becomes easier to wash and dry, and body pressure distribution is also improved.

[0020] By forming the convex portion by profiling into a wedge-shaped cross section with a thickness smaller on the top side than on the base side, the mattress becomes easier to wash and dry, and body pressure distribution is further improved. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a perspective view of a mattress according to one embodiment of the present invention. [Figure 2] 2 is a cross-sectional view taken along line 2-2 of FIG. 1. [Figure 3] FIG. 2 is an exploded perspective view of the mattress of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION

[0022] One embodiment of the mattress of the present invention will be described below. The mattress of the present invention is suitable for use by placing it on a bed. The mattress 10 shown in Figures 1 to 3 is approximately rectangular in plan view and is made up of a laminate of a first polyurethane foam 21, an adhesive layer 25, a second polyurethane foam 31, and a third polyurethane foam 41.

[0023] The first polyurethane foam 21 and the second polyurethane foam 31 are laminated with an adhesive layer 25 sandwiched therebetween and bonded together by the adhesive layer 25 . The first polyurethane foam 21 has a lower hardness than the second polyurethane foam 31. The hardness of the first polyurethane foam 21 is 120N, and preferably in the range of 90N to 150N. The first polyurethane foam 21 is preferably a soft polyurethane foam with an open-cell structure. Either the first polyurethane foam 21 with a low hardness or the second polyurethane foam 31 with a high hardness may be on the side that comes into contact with the human body (upper side), but preferably the first polyurethane foam 21 with a low hardness is on the side that comes into contact with the human body (upper side).

[0024] The adhesive layer 25 bonds the first polyurethane foam 21 to the second polyurethane foam 31 and the third polyurethane foam 41. Examples of adhesives that constitute the adhesive layer 25 include polyurethane-based adhesives. The adhesive layer 25 is provided by coating or the like on the surface of either the first polyurethane foam 21 or the second polyurethane foam 31. In the illustrated example, the adhesive layer 25 is provided by coating on the surface of the second polyurethane foam 31.

[0025] The second polyurethane foam 31 has a higher hardness than the first polyurethane foam 21. The hardness of the second polyurethane foam 31 is 210N, preferably in the range of 170N to 250N. The difference in hardness between the second polyurethane foam 31 and the first polyurethane foam 21 is 90N, preferably 80N to 100N. By making the hardness of the second polyurethane foam 31 higher than that of the first polyurethane foam 21, the side that comes into contact with the human body is made of the first polyurethane foam 21 with a lower hardness and the side that faces the floor is made of the second polyurethane foam 31 with a higher hardness, thereby improving the distribution of body pressure due to the increased contact area. In addition, the second polyurethane foam 31 is preferably a soft polyurethane foam with an open-cell structure.

[0026] The third polyurethane foam 41 is provided at both ends in the width direction W of the mattress 10, sandwiched between either the first polyurethane foam 21 or the second polyurethane foam 31 and the adhesive layer 25. In other words, the surface of the third polyurethane foam 41 provided at both ends in the width direction W of the mattress 10 that comes into contact with either the first polyurethane foam 21 or the second polyurethane foam 41 is not covered with the adhesive layer 25, and the other surfaces are covered with the adhesive layer 25. In the illustrated example, the third polyurethane foam 41 is sandwiched between the first polyurethane foam 21 and the adhesive layer 25, and the surface that comes into contact with the first polyurethane foam 21 is not covered with the adhesive layer 25.

[0027] The third polyurethane foam 41 is formed in a long strip shape along the longitudinal direction L of the mattress 10. The thickness of the third polyurethane foam 41 is preferably thin, between 1 mm and 10 mm, and more preferably between 5 mm and 7 mm. The width of the third polyurethane foam 41 is preferably between 70 mm and 130 mm, and more preferably between 90 mm and 110 mm. If the width exceeds 130 mm, the width in the supine position becomes narrow. If it is less than 70 mm, the support strength in the edge-sitting position becomes weak.

[0028] The third polyurethane foam 41 is provided at both ends of the width direction W of the mattress 10, spaced apart from each other. The third polyurethane foam 41 is preferably provided at distances a and b from both the end 11 in the width direction W and the end 12 in the length direction L of the mattress 10. The values ​​of a and b are preferably 40 mm to 60 mm. In the sections from the end 11 in the width direction W and the end 12 in the length direction L of the mattress 10 to the third polyurethane foam 41, the first polyurethane foam 21 and the second polyurethane foam 31 are bonded by the adhesive layer 25, making it difficult for the third polyurethane foam 41 to shift or separate from the mattress 10.

[0029] The third polyurethane foam 41 has a higher hardness than the second polyurethane foam 31. That is, there is a relationship of [hardness of the third polyurethane foam 41 > hardness of the second polyurethane foam 31 > hardness of the first polyurethane foam 21]. The hardness of the third polyurethane foam 41 is 10 kPa, and is preferably in the range of 9 kPa to 11 kPa. By making the hardness of the third polyurethane foam 41 higher than that of the first polyurethane foam 21 and the second polyurethane foam 31, it is possible to prevent instability in posture caused by large elastic deformation when a mattress user or caregiver sits or leans on both ends of the mattress in the width direction, thereby supporting caregiving work, etc.

[0030] The third polyurethane foam 31 is made of a polyurethane foam according to ASTM D 3 The ventilation rate conforming to 574 is 70 liters / min or more, and the material is highly breathable. The more preferable ventilation rate is 70 to 120 liters / min.

[0031] The third polyurethane foam 41 provided at both ends of the mattress 10 in the width direction W has a surface that is in contact with either the first polyurethane foam 21 or the second polyurethane foam 31 (the first polyurethane foam 21 in the illustrated example) that is not covered with an adhesive layer 25, and the third polyurethane foam 41 is made of a material that conforms to ASTM D 3 As the mattress has high breathability with an airflow rate of 70 l / min or more in accordance with JIS No. 574, when the mattress is washed, the cleaning water that gets into the center of the mattress can evaporate to the outside through the highly breathable third polyurethane foam when the mattress is dried, resulting in good drying properties.

[0032] Furthermore, the third polyurethane foam 41 preferably has an elongation in accordance with JIS K6400-5 of 70% or more, more preferably 70% to 100%. By making the elongation of the third polyurethane foam 41 70% or more, there is no risk of the third polyurethane foam 41 breaking when it expands or contracts due to pressure being applied to both ends of the width direction W of the mattress 10 during nursing care or the like. Furthermore, the third polyurethane foam 41 is preferably a flexible polyurethane foam with an open-cell structure.

[0033] Preferably, at least one of the first polyurethane foam 21 and the second polyurethane foam 31 has a surface provided with irregularities 15 by profiling, and more preferably, both the first polyurethane foam 21 and the second polyurethane foam 31 have irregularities. By providing irregularities by profiling, the surface area of ​​the mattress 10 is increased, improving the washability and drying properties of the mattress 10 and also improving body pressure distribution. The profiled surface area is preferably at least two times and no more than four times that of the flat surface without profiling. If it is less than two times, drying efficiency will be reduced. If it exceeds four times, the wedge shape will be weakened and durability will be reduced.

[0034] Profile processing is a well-known method in which polyurethane foam is compressed from both sides using uneven rollers or a mold, the compressed polyurethane foam is cut between the uneven rollers or molds to divide it into two, and then the compression is released to allow it to return to its original shape, thereby forming unevenness on the divided surfaces of the polyurethane foam.

[0035] The shape of the unevenness 15 formed by the profile processing may be a wave shape or the like, but as in this embodiment, a wedge-shaped cross section in which the thickness of the convex portion 16 is smaller at the top side than at the base side of the convex portion 16 is preferable. By using this cross-sectional shape, the body pressure distribution is further improved and the cleaning and drying properties are also improved. [Example]

[0036] The first polyurethane foam 21 has a density of 25 kg / m 3The specimen used was an open-cell flexible polyurethane foam manufactured by Inoac Corporation (product name: EAH-M), with a hardness of 120N, elongation of 80% in accordance with JIS K6400-5, and dimensions of 60mm thick x 910mm wide x 1910mm long. One side had a wedge-shaped convexity profiled on it, giving it a surface area approximately 2.8 times that of the flat surface. The surface area of ​​the profiled, convex-convex surface was calculated using a 100mm x 100mm square specimen, while the surface area of ​​the unprofiled flat surface was calculated using the same width x length method.

[0037] For the adhesive layer 25, a polyurethane adhesive, trade name: Formlite 0135B, manufactured by BASF INOAC Polyurethanes Ltd., was used. The second polyurethane foam 31 has a density of 35 kg / m 3 The specimen used was an open-cell flexible polyurethane foam manufactured by Inoac Corporation (product name: EAH-H), with a hardness of 210N, an elongation of 80% in accordance with JIS K6400-5, and dimensions of 40mm thick x 910mm wide x 1910mm long. One side had a wedge-shaped convexity profiled on it, giving it a surface area approximately 2.8 times that of the flat surface. The surface area of ​​the profiled, convex-convex surface was calculated using a 100mm x 100mm square test piece, while the surface area of ​​the unprofiled flat surface was calculated using the same width x length method.

[0038] As a third polyurethane foam 41, a density of 50 kg / m 3 , hardness 10kPa, elongation 70% according to JIS K6400-5, ASTM D 3 The ventilation was 70 l / min in accordance with 574, and the product name: CF-EMO, a flexible polyurethane foam with an open-cell structure manufactured by Inoac Corporation, was used, with dimensions of 5 mm thick x 100 mm wide x 1800 mm long.

[0039] The surface of the second polyurethane foam 31 opposite to the profiled surface is coated with 40 g / m 2was applied to the entire surface using a roll coater to form an adhesive layer 25, and a third polyurethane foam 41 was placed on both ends of the adhesive layer 25 in the width direction W, 50 mm from the end 11 in the width direction W and 55 mm from the end 12 in the length direction L. The third polyurethane foam 41 was then laminated on the surface opposite to the profiled surface of the first polyurethane foam 21 so as to cover the third polyurethane foam 41 and adhesive layer 25. In this laminated state, the profiled surfaces of the first polyurethane foam 21 and the profiled surfaces of the second polyurethane foam 31 were pressed together with a mold and heated at 140°C for 260 seconds to cure the adhesive layer 25, thereby producing the mattress 10 shown in Figures 1 to 3.

[0040] The mattresses manufactured in the examples provide high posture stability when the mattress user or caregiver sits or leans on either end of the mattress widthwise, and also dry easily when washed. [Explanation of symbols]

[0041] 10 Mattress 11 Widthwise edge 12 Lengthwise ends 15Profile processing unevenness 16 Convex part by profile machining 21 The First Polyurethane Foam 25 Adhesive layer 31 Second Polyurethane Foam 41 The third polyurethane foam

Claims

1. A mattress in which a first polyurethane foam and a second polyurethane foam having a hardness higher than that of the first polyurethane foam are laminated and bonded together with an adhesive layer sandwiched therebetween, A mattress characterized in that a third polyurethane foam having a hardness higher than that of the second polyurethane foam and an air permeability of 70 l / min or more in accordance with ASTM D3574 is provided at both ends in the width direction of the mattress, sandwiched between either the first polyurethane foam or the second polyurethane foam and the adhesive layer.

2. 2. The mattress according to claim 1, wherein the third polyurethane foam has an elongation of 70% or more in accordance with JIS K6400-5.

3. 3. The mattress according to claim 1, wherein the third polyurethane foam has a thickness of 1 mm to 10 mm.

4. 4. The mattress of claim 1, wherein the third polyurethane foam is positioned away from the width and length ends of the mattress.

5. 5. A mattress according to claim 1, wherein the surface of at least one of the first polyurethane foam and the second polyurethane foam is provided with unevenness by profiling.

6. 6. The mattress of claim 5, wherein the profiled surface area is at least two times and at most four times the area of ​​the unprofiled flat surface.

7. 7. The mattress according to claim 5, wherein the convex portion formed by the profile processing has a wedge-shaped cross section with a thickness smaller on the top side than on the base side.

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