Bedding

Abstract

To provide a mattress for effectively improving quality of sleep and giving excellent sleeping comfort.SOLUTION: A mattress 1 is constituted by an organized resin net-shaped structure where a plurality of fiber-like molten resins is entangled and also partially thermally fused. Soft layers and hard layers harder than the soft layers are alternately laminated by four layers or more so as to form even-numbered lamination in the thickness direction. The organized resins of the soft layer and the organized resins of the hard layer are entangled in a boundary between the soft layer and the hard layer. The highest layer 10 is the soft layer and is thicker than any other layer of the respective layers. The lowest layer 60 is the hard layer and is thinner than any other layer of the respective layers.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a mattress made of a knitted resin network structure. [Background technology]

[0002] Patent Document 1 discloses a mattress comprising a first cushion layer located at the bottom of the mattress, a second cushion layer stacked on the top layer of the mattress, and a first intermediate layer and a second intermediate layer stacked between the first and second cushion layers, the first cushion layer, the second cushion layer and the second intermediate layer being made of cushioning material, the first intermediate layer having an elastic portion that forms a three-dimensional network structure made of a resin material, the second intermediate layer having a head support portion corresponding to the user's head side, a lumbar support portion corresponding to the user's waist side and a foot support portion corresponding to the user's feet side, and the lumbar support portion being harder than the head support portion and the foot support portion. Patent Document 2 discloses a mattress made of a two-layer knitted resin network structure in which the lower back and buttocks, back, and leg areas have different bulk densities. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-99542 [Patent Document 2] Japanese Patent Application Publication No. 2017-086321 Summary of the Invention [Problem to be solved by the invention]

[0004] As shown in Patent Documents 1 and 2, various beddings have been proposed in the past with the aim of improving the quality of sleep, but there is a demand for beddings that are even more comfortable to sleep on. Therefore, an object of the present invention is to provide a mattress that is comfortable to sleep on and effectively improves the quality of sleep. [Means for solving the problem]

[0005] The mattress 1 of the present invention described in claim 1 is a mattress made of a knitted resin network structure in which a plurality of filamentous molten resins are intertwined and partially heat-welded, and is made up of four or more layers of soft layers and hard layers harder than the soft layers, alternately stacked in an even number in the thickness direction. At the boundary between the soft and hard layers, the knitted resin of the soft layer and the knitted resin of the hard layer are intertwined, the top layer 10 is a soft layer and is the thickest of all the layers, and the bottom layer 60 is a hard layer. In other words, the thickness of the hard intermediate layers between the top layer 10 and the bottom layer 60 is greater than the thickness of the soft intermediate layers. It is characterized by:

[0006] The present invention as set forth in claim 2 is characterized in that in the mattress 1 as set forth in claim 1, the bottom layer 60 has the smallest thickness among all the layers.

[0007] Claim 3 The invention as described is defined in claims 1 The bedding 1 described above is characterized in that in the intermediate layer, the soft layers have the same thickness and the hard layers have the same thickness.

[0008] Claim 4 The present invention as described is as follows: 3 The bedding (1) according to any one of the above is characterized in that the wire diameter of the woven resin in the soft layer is smaller than the wire diameter of the woven resin in the hard layer, and the bulk density of the soft layer is smaller than the bulk density of the hard layer.

[0009] Claim 5 The present invention as described is as follows: 4 The bedding 1 described in any one of the above items comprises, in the width direction, a central region 70 located in the center, end regions 80 located at both ends, and an intermediate region 90 located between the central region 70 and the end region 80, wherein the end region 80 is harder than the central region 70, and the intermediate region 90 is harder than the central region 70 but softer than the end region 80, and at the boundary between the central region 70 and the intermediate region 90, the woven resin of the central region 70 and the woven resin of the intermediate region 90 are entangled, and at the boundary between the intermediate region 90 and the end region 80, the woven resin of the intermediate region 90 and the woven resin of the end region 80 are entangled.

[0010] Claim 6 The invention as described is defined in claims 5 The bedding (1) described above is characterized in that the intermediate region (90) is made up of a plurality of small regions with different hardness in the width direction, and among adjacent small regions, the one closer to the central region (70) is softer.

[0011] Claim 7 The present invention as described is as follows: 6 The bedding 1 according to any one of the above is characterized in that it has six layers. [Effects of the Invention]

[0012] According to the present invention, it is possible to provide a mattress that is comfortable to sleep on and effectively improves the quality of sleep. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a conceptual diagram showing the layer structure of a mattress according to an embodiment of the present invention; [Figure 2] Conceptual diagram showing the multi-area structure of the bedding [Figure 3] FIG. 1 shows a manufacturing apparatus for the bedding. DETAILED DESCRIPTION OF THE INVENTION

[0014] The bedding according to the first embodiment of the present invention is a bedding consisting of an woven resin network structure in which a plurality of filamentous molten resins are entangled and partially heat-welded, and is composed of four or more layers of soft layers and hard layers that are harder than the soft layers stacked alternately in an even number in the thickness direction, with the woven resin of the soft layer and the woven resin of the hard layer being entangled at the boundary between the soft and hard layers, and the top layer being a soft layer and the thickest of all the layers, and the bottom layer being a hard layer and the thinnest of all the layers. According to this embodiment, it is possible to provide a mattress that is comfortable to sleep on and does not cause the user to feel like they are hitting the bottom.

[0015] The second embodiment of the present invention is a mattress according to the first embodiment, in which the thickness of the hard intermediate layers located between the top layer and the bottom layer is greater than the thickness of the soft intermediate layers. According to this embodiment, bedding that is more comfortable to sleep on can be provided.

[0016] A third embodiment of the present invention is the bedding according to the second embodiment, wherein in the intermediate layer, the soft layers have the same thickness and the hard layers have the same thickness. According to this embodiment, it is possible to provide a mattress that is even more comfortable to sleep on.

[0017] A fourth embodiment of the present invention is a bedding according to any one of the first to third embodiments, wherein the wire diameter of the woven resin in the soft layer is smaller than the wire diameter of the woven resin in the hard layer, and the bulk density of the soft layer is smaller than the bulk density of the hard layer. According to this embodiment, the difference in hardness (repulsion force) between the soft layer and the hard layer can be set with high precision.

[0018] The fifth embodiment of the present invention is a bedding mattress according to any one of the first to fourth embodiments, which comprises, in the width direction, a central region located in the center, end regions located at both ends, and an intermediate region located between the central region and the end region, wherein the end regions are harder than the central region, and the intermediate region is harder than the central region and softer than the end regions, and at the boundary between the central region and the intermediate region, the woven resin of the central region and the woven resin of the intermediate region are intertwined, and at the boundary between the intermediate region and the end region, the woven resin of the intermediate region and the woven resin of the end region are intertwined. According to this embodiment, it is possible to provide a mattress that allows the user to turn over easily and has excellent shape retention and cushioning properties.

[0019] The sixth embodiment of the present invention is a mattress according to the fifth embodiment, in which the intermediate region is made up of a plurality of small regions of different hardness in the width direction, and among adjacent small regions, the one closer to the central region is softer. According to this embodiment, it becomes easier to turn over in sleep, further improving the quality of sleep.

[0020] A seventh embodiment of the present invention is a bedding according to any one of the first to sixth embodiments, which has six layers. According to this embodiment, bedding that is excellent in sleeping comfort can be provided. [Example]

[0021] Hereinafter, a bedding according to one embodiment of the present invention will be described. FIG. 1 is a conceptual diagram showing the layer structure of the mattress according to this embodiment, showing the mattress as viewed from the side. The mattress 1 is made of a knitted resin network structure in which multiple filamentous molten resin threads are entangled and partially heat-welded. Because the shape of the knitted network structure itself forms the shape of the mattress, the mattress 1 can be used as is without putting it in a cover. The knitted resin network structure is formed by melt-kneading a thermoplastic resin at a predetermined temperature, allowing the molten resin to flow down in the form of threads, and then cooling the melted resin. The thermoplastic resin may be, for example, polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polytetrafluoroethylene, or acrylonitrile butadiene styrene resin, and these may be used alone or in combination. The knitted resin network structure manufactured using thermoplastic resin as a raw material can be recycled after use and reused as a raw material for knitted resin network structures, etc. Furthermore, the knitted resin network structure can be washed using water, etc., making it easy to keep the bedding 1 clean. Bedding 1 made of a woven resin network structure can be used as a mattress, a futon, or the like. For example, when provided as a single-size mattress, it is molded to have a length (length) of 1950 mm and a width (width) of 1000 mm, based on the general length and width dimensions of mattresses. The thickness of the woven resin network structure is generally set in the range of approximately 150 mm to 300 mm, but is not limited to this range. A thinner woven resin network structure becomes lighter and more flexible, while a thicker woven resin network structure becomes slightly less light and less flexible but has a firmer feel. Therefore, by changing the thickness, bedding 1 can be provided according to the user's preferences.

[0022] The mattress 1 is made up of four or more layers of soft layers alternately stacked in the thickness direction, with hard layers harder than the soft layers. At the boundary between the soft and hard layers, the knitted resin of the soft layer and the knitted resin of the hard layer are intertwined. Because the knitted resins are intertwined at the boundary between each layer, the mattress has better shape retention and cushioning than a mattress made by simply stacking knitted resin network structures formed layer by layer. The thickness of the boundary portion is approximately 10 mm. The number of layers is an even number, so that one of the top layer 10 and the bottom layer 60 is a soft layer and the other is a hard layer. Although it is possible to have four or eight layers, a mattress with six layers, as shown in Figure 1, can provide excellent comfort. The top layer 10, which is located at the top during use, is a soft layer and has the greatest thickness of all the layers. The bottom layer 60, which is located at the bottom during use, is a hard layer and has the smallest thickness of all the layers. This results in a mattress that is comfortable to sleep on and does not feel like you are hitting the bottom.

[0023] In the multiple intermediate layers located between the top layer 10 and the bottom layer 60, the thickness of the hard intermediate layers is made thicker than the thickness of the soft intermediate layers. This allows for a mattress that is more comfortable to sleep on. In the case of a six-layer mattress, as shown in Figure 1, the third and fifth intermediate layers (third layer 30 and fifth layer 50) from the top are soft layers, and the second and fourth intermediate layers (second layer 20 and fourth layer 40) from the top are hard layers. In addition, in the intermediate layer, it is preferable that the soft layers (third layer 30 and fifth layer 50) have the same thickness, and the hard layers (second layer 20 and fourth layer 40) have the same thickness. This makes it possible to provide a mattress that is even more comfortable to sleep on. In this embodiment, the mattress 1 has a thickness T1 of the top layer 10 (soft layer) of approximately 35 mm to 40 mm, a thickness T2 of the second layer 20 and fourth layer 40 (hard layer) of approximately 30 mm, a thickness T3 of the third layer 30 and fifth layer 50 (soft layer) of approximately 20 mm, and a thickness T4 of the bottom layer 60 (hard layer) of approximately 10 mm to 15 mm, so that if the thickness T1 is "1", the thickness T2 is "approximately 0.75 to 0.85", the thickness T3 is "approximately 0.5 to 0.57", and the thickness T4 is "approximately 0.25 to 0.42".

[0024] The wire diameter of the knitted resin in the soft layers (top layer 10, third layer 30, and fifth layer 50) is smaller than the wire diameter of the knitted resin in the hard layers (second layer 20, fourth layer 40, and bottom layer 60). In addition, the bulk density of the soft layers is smaller than the bulk density of the hard layers. This allows the difference in hardness (rebound force) between the soft and hard layers to be accurately set. In the mattress 1 of this embodiment, the wire diameter of the knitted resin in the soft layer is about 0.7 mm, and the wire diameter of the knitted resin in the hard layer is about 0.8 mm, so that the wire diameter of the knitted resin in the hard layer is about 1.1 times the wire diameter of the knitted resin in the soft layer. Also, in the mattress 1 of this embodiment, the bulk density of the soft layer is about 0.035 g / cm 3 , the bulk density of the hard layer is 0.046 g / cm 3 In this way, the bulk density of the hard layer is about 1.3 times the bulk density of the soft layer. The bulk density of the entire mattress 1 is about 0.0500 g / cm 3 Bulk density is calculated by dividing weight (g) by volume (cm3 ) can be found.

[0025] FIG. 2 is a conceptual diagram showing the multi-region structure of the mattress according to this embodiment, showing the mattress as viewed from above. The width direction W of the mattress 1 is made up of a central region 70 located in the center, end regions 80 located at both ends, and an intermediate region 90 located between the central region 70 and the end region 80. The end regions 80 are harder than the central region 70. The inter-region 90 is harder than the central region 70 but softer than the end regions 80. These hardnesses (resilience) are set by varying the bulk density of each region. The bulk density of the central region 70 is smaller than that of the inter-region 90, which in turn is smaller than that of the end regions 80. In this way, by making the center soft and gradually harder toward the ends in the width direction, it is possible to create a mattress that makes it easy to turn over in bed. At the boundary between the central region 70 and the intermediate region 90, the woven resin of the central region 70 and the woven resin of the intermediate region 90 are intertwined, and at the boundary between the intermediate region 90 and the end region 80, the woven resin of the intermediate region 90 and the woven resin of the end region 80 are intertwined. By intertwining the woven resins at the boundary between each region in this way, the mattress has better shape retention and cushioning properties than if the woven resin network structures formed in each region were simply lined up in the width direction.

[0026] Although not shown in the drawings, the intermediate region 90 can be subdivided to provide multiple small regions with different hardness in the width direction. In this case, the small regions are provided as first small regions that contact both sides of the central region 70 and second small regions that contact the edge regions 80, and the first small regions are made softer than the second small regions. In this way, the intermediate region 90 is made up of multiple small regions with different hardness in the width direction, and between adjacent small regions, the one closer to the central region 70 is made softer, allowing for more precise changes in hardness from the central region 70 to the end region 80. This makes it easier for the user to turn over in their sleep, further improving the quality of sleep.

[0027] FIG. 3 is a diagram showing a bedding manufacturing apparatus according to this embodiment. The manufacturing apparatus according to this embodiment includes an extruder 110 that melts and kneads a thermoplastic resin at a predetermined temperature to form a molten resin and extrudes the molten resin at a predetermined extrusion speed, a resin pool 130 that receives the molten resin extruded from the extruder 110 and causes the molten resin to flow down in threads from a number of holes (nozzles) in a bottom surface 131, a cooling water tank 140 that stores cooling water, and a take-up machine 150 that takes up downward a knitted resin 121 formed by cooling the thread-like molten resin 120 that flows down from the resin pool 130 with the cooling water. The take-up machine 150 has a plurality of take-up rollers 151 facing each other and is disposed within the cooling water tank 140. A guider 170 is provided between the resin pool 130 and the take-up machine 150. The filamentous molten resin 120 is formed as it flows down through holes in the bottom surface 131 of the resin pool 130. The woven resin 121, which is formed by cooling the filamentous molten resin 120 with cooling water, is drawn up by a drawer 150 to the bottom plate side of the cooling water tank 140. After passing through the drawer 150, the woven resin 121 is drawn up diagonally upward while being cooled in the cooling water by a plurality of conveying rollers 160, which are drawing-up members arranged in the cooling water tank 140, and conveyed out of the cooling water tank 140. After that, the woven resin network structure is formed as the mattress 1 by cooling and cutting to a predetermined size. In this embodiment, the direction perpendicular to the extrusion direction is the thickness direction of the mattress 1.

[0028] The central region 70, the intermediate regions 90, and the end regions 80 of the mattress 1 are formed by varying the density in the direction parallel to the extrusion direction. The density variation in the direction parallel to the extrusion direction is achieved, for example, by changing the take-up speed of the take-up machine 150 at predetermined time intervals. When the density variation is achieved by changing the take-up speed, the speed at which the take-up machine 150 takes up the knitted resin 121 is set to a first speed, a second speed slower than the first speed, and a third speed slower than the first speed but faster than the second speed. The portion of the knitted resin 121 taken up by the take-up machine 150 at the second speed has a higher bulk density than the portion taken up at the first speed, so the portion taken up at the first speed becomes the central region 70, which is a sparse portion with the lowest bulk density, the portion taken up at the second speed becomes the end region 80, which is a dense portion with the highest bulk density, and the portion taken up at the third speed becomes the intermediate region 90, which is a portion with a bulk density intermediate between the above. Therefore, by repeating the pattern of the take-up speed of the take-up machine 150 being second speed → third speed → first speed → third speed → second speed, it is possible to manufacture a mattress 1 having an intermediate region 90 between the central region 70 and the end region 80 in the direction parallel to the extrusion direction. Here, by varying the duration of each speed, for example, by making the take-up time at the second speed the longest, the take-up time at the first speed the next longest, and the take-up time at the third speed the shortest, it is possible to vary the width of each region. Note that if the intermediate region 90 is subdivided to form smaller regions, the take-up speed of the take-up machine 150 can be set in even finer increments. The density variation in the direction perpendicular to the extrusion direction is achieved, for example, by changing the diameter of the holes provided in the bottom surface 131 of the resin pool 130 within a predetermined range. When the density variation is achieved by changing the diameter of the holes in the resin pool 130, the diameter of the holes corresponding to the soft layer is made smaller than the diameter of the holes corresponding to the hard layer. [Explanation of symbols]

[0029] 1 Bedding 10 Top Floor 20 Second layer 30 Third layer 40 Fourth layer 50 Fifth layer 60 lowest floor 70 Central area 80 End area 90 fields

Claims

1. A mattress comprising a knitted resin network structure in which a plurality of filamentous molten resins are entangled and partially heat-welded, In the thickness direction, soft layers and hard layers harder than the soft layers are alternately stacked in an even number of four or more layers, At the boundary between the soft layer and the hard layer, the knitted resin of the soft layer and the knitted resin of the hard layer are entangled, The top layer is the soft layer and has the largest thickness among the layers, and the bottom layer is the hard layer, A mattress characterized in that the thickness of the multiple intermediate layers located between the top layer and the bottom layer is greater than the thickness of the intermediate layers that are hard layers.

2. 2. The mattress according to claim 1, wherein the bottom layer has the smallest thickness of all the layers.

3. 2. The bedding according to claim 1, wherein in the intermediate layer, the soft layers have the same thickness and the hard layers have the same thickness.

4. A bedding set according to any one of claims 1 to 3, characterized in that the wire diameter of the woven resin in the soft layer is smaller than the wire diameter of the woven resin in the hard layer, and the bulk density of the soft layer is smaller than the bulk density of the hard layer.

5. In the width direction, the sheet comprises a central region located at the center, end regions located at both ends, and intermediate regions located between the central region and the end regions, the end regions being harder than the central region; the intermediate region being harder than the central region and softer than the end regions; At the boundary between the central region and the intermediate region, the knitted resin of the central region and the knitted resin of the intermediate region are entangled, 5. The bedding according to claim 1, wherein the woven resin of the intermediate region and the woven resin of the end region are intertwined at the boundary between the intermediate region and the end region.

6. 6. The mattress according to claim 5, wherein the intermediate region is made up of a plurality of small regions of different hardness in the width direction, and between adjacent small regions, the one closer to the central region is softer.

7. 7. The mattress according to claim 1, wherein the mattress has six layers.

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