Combination bedding and mattress overlays

Abstract

To provide combination bedding to be used as a bedding mat by combination with a mattress and having a structure to provide sufficient sleep while securing a wide range of a front surface.SOLUTION: Combination bedding includes: a base to be arranged on a floor surface; and a mattress to be placed on an upper surface of the base. The base is constituted by combining a plurality of partial bases so as to allow the upper surfaces of the partial bases to continue each other. The mattress is formed to have a size to cover a nearly whole surface of the upper surface of the base.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to combination bedding and overlay mattresses that use multiple section platforms and mattresses. [Background technology]

[0002] Everyday items such as bedding, rugs, and cushions that use foam resins such as urethane foam are designed so that when a person lies down on them, the parts that use the foam resin deform and collapse, expanding the surface area of ​​the contact area to absorb the weight and pressure.The foam resin contains air bubbles when molded, and after molding, when pressure is applied, the air bubbles deform significantly, reducing their volume, and then return to their original shape when the pressure is released.

[0003] Incidentally, although it depends on family structure and housing circumstances, there are cases where multiple sleepers use single-size futons or mattresses side by side at the same time, and even if each futon or mattress is single-size (e.g., 180 cm x 90 cm), by using them side by side, it can be used with usability similar to that of a king-size futon or mattress (e.g., 200 cm x 200 cm). Gap pads (see, for example, Patent Documents 1 and 2) are also known to fill the gap when two futons or mattresses are placed side by side in this way. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Utility model registration No. 3215277 [Patent Document 2] Utility Model Registration No. 3202978 Summary of the Invention [Problem to be solved by the invention]

[0005] However, even with the use of gap pads, small children may end up sleeping in a way that could damage their health if their hands or feet get stuck in between the edges of the gap pads. Also, while there is a desire to use larger bedding to have more space to lie down, housing conditions tend to discourage people from placing platforms that take up a large amount of floor space, and when using a sturdy, fixed platform or mat, it can sometimes get in the way.

[0006] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a combination bedding that is used as a mattress in combination with a mattress and has a structure that allows a user to sleep comfortably while securing a wide surface area. [Means for solving the problem]

[0007] In order to solve the above-mentioned technical problems, the combination bedding of the present invention is a combination bedding comprising a base placed on a floor surface and a mattress placed on the top surface of the base, The platform is provided with a futon, a bed or a mattress, The upper surfaces of the mattresses are joined together so that they are continuous. It is made of foaming synthetic resin material, high-resilience polyester cotton heat treatment material, or a combination of these. The cover is formed to a size that covers almost the entire upper surface of the base.

[0008] In the combination bedding according to the embodiment of the present invention, the mattress can be made of various materials, such as foamed synthetic resin, high-resilience polyester cotton heat-treated material, or a combination thereof. Examples of foamed synthetic resin include soft or hard urethane resin, styrene resin, ethylene resin, propylene resin, ethylene-vinyl acetate copolymer resin, and vinyl chloride resin. The high-resilience polyester cotton heat-treated material can be prepared by the manufacturing method described below, and a blend of polyester cotton and cotton can also be used.

[0009] The mattress used in the combination bedding according to a preferred embodiment of the present invention can be formed by cutting it to the desired size. For example, the size across the top surface of the mattress's multiple sub-bases is greater than 140cm square and less than 300cm square, and more preferably greater than 175cm square and less than 245cm square. The length and width are not limited to sizes that are the same, and either the length or width may be longer.

[0010] Furthermore, the thickness of the mattress used in the combination bedding according to the preferred embodiment of the present invention can be, for example, in the range of 1 cm to 4 cm, more preferably in the range of 1.5 cm to 3.3 cm. Furthermore, in the mattress of the combination bedding according to the example of the present invention, the weight per unit area is 1.2 kg / m. 2 or more, more preferably 1.5 kg / m 2 Or it can be more.

[0011] Furthermore, in the mattress used in the combination bedding according to a preferred embodiment of the present invention, the surface repulsive force of the mattress can be set so that, for example, when a golf ball is allowed to freely fall from a height of 60 cm, the height reached by the initial repulsive force is approximately 25 cm or more, more preferably approximately 28 cm or more.

[0012] Such combination bedding has multiple partial bases that make up the base, and the multiple partial bases can be constructed with various components depending on the situation. In this specification, the term "partial base" is broadly interpreted as meaning any component that can support a mattress on a surface. Examples of partial bases include futons, single-size and queen-size beds, as well as sofas, cushions, and other materials such as wooden boxes, cardboard boxes, mandarin orange boxes, tea boxes, and containers for transporting alcohol bottles, as well as combinations thereof. Parts of the partial base may be fixed to buildings, etc. Furthermore, this is not necessarily limited to bedding for residential use, but can be applied to any form of use where a person lies down or sits in a commercial setting such as a hospital or hotel, or in a vehicle or other facility. Mattresses are not necessarily limited to those used permanently, but also include temporary use.

[0013] The partial bases used in the combination bedding of this embodiment can be, for example, boxes of similar size combined together, or foldable materials such as foldable cardboard. Also, containers for storing liquids such as water can be used as partial bases, and the upper surfaces of the connected partial bases can be sloped in part.

[0014] In addition, the overlay mattress according to an embodiment of the present invention is an overlay mattress used in the assembled bedding described above, characterized in that the size of the overlay mattress is such that it covers almost the entire top surface of the base. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic perspective view showing an example of a combination bedding set using a hardening overlay mattress on a pair of mats according to an embodiment of the present invention. [Figure 2] FIG. 1 is a schematic top view of a hardening overlay type mattress used in an example of a combination bedding according to an embodiment of the present invention. [Figure 3]1 is a perspective view showing a state in which a combination bedding according to an embodiment of the present invention is used. [Figure 4] FIG. 1 is a schematic diagram illustrating a rebound force comparison experiment using a golf ball conducted on a hardened overlay-type mattress according to an embodiment of the present invention. [Figure 5] 1 is a flow chart illustrating an example of a method for manufacturing a hardening overlay type mattress used in the combination bedding of an embodiment of the present invention. [Figure 6] FIG. 1 is a schematic perspective view showing an example of a combination bedding set in which a hardening overlay mattress is used on two pairs of mats according to an embodiment of the present invention. [Figure 7] FIG. 1 is a schematic perspective view showing an example of combination bedding in which a hardening overlay mattress is used on three mats according to an embodiment of the present invention. [Figure 8] FIG. 1 is a schematic perspective view showing an example of combination bedding in which a hardening overlay mattress is used on four mats according to an embodiment of the present invention. [Figure 9] FIG. 1 is a schematic perspective view showing an example of combination bedding in which a hardening overlay mattress is used on two mats of different sizes according to an embodiment of the present invention. [Figure 10] FIG. 10 is a perspective view showing an example in which a foldable cardboard box is used as a partial base for use in the combination bedding of an embodiment of the present invention. [Figure 11] FIG. 10 is a perspective view showing an example in which a container for storing water is used as a partial base for use in the combination bedding of an embodiment of the present invention. [Figure 12] FIG. 10 is a perspective view showing an example in which a drawer storage furniture is used as a partial base for use in the combination bedding of the embodiment of the present invention. [Figure 13] FIG. 10 is a schematic cross-sectional view of a mattress according to a modified embodiment of the present invention. [Figure 14] FIG. 10 is a schematic cross-sectional view of a mattress according to another modified example of an embodiment of the present invention. [Figure 15] FIG. 10 is a perspective view showing an example of a combination bedding in which a member having a slope on one side is arranged as a partial base used in the combination bedding of an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0016] An embodiment of the combination bedding of the present invention will be described with reference to the drawings. Fig. 1 is a schematic perspective view illustrating the combination bedding using a hardening overlay mattress 10. Mattresses 12 and 16 are arranged side by side as a pair of partial bases, with a small gap 14 between these mats 12 and 16 even when arranged side by side. The upper surfaces of these mats 12 and 16 allow sleepers to lie in any position, and the hardening overlay mattress 10 is arranged to cover the upper surfaces, resulting in a combination bedding that can be used as a large-sized bed as a whole.

[0017] The term "mattress" as used herein is broadly understood and may be used alone or may include, for example, a quilted or overlaying cover. The hardened overlay mattress 10 can also be used with a sheet or towel placed over it. The term also broadly refers to a pair of partial platforms placed under the hardened overlay mattress 10, and includes not only futons and single-size and queen-size beds, but also sofas, cushions, wooden boxes, cardboard, and other various materials, as well as combinations thereof. One of the partial platforms may be fixed to a building or other structure. Furthermore, the term is not necessarily limited to partial platforms for residential use, but can be used in any form, such as in commercial facilities such as hospitals and hotels, vehicles, or other facilities where people lie down or sit. Hardened overlay mattresses are not necessarily used permanently, and temporary use is also included.

[0018] Various materials can be used to form the hardening overlay-type mattress 10, but in this example, the hardening overlay-type mattress 10 is formed from a heat-treated high-resilience polyester cotton material. Alternatively, the hardening overlay-type mattress 10 can be formed from, for example, a foamed synthetic resin material, or a combination of a heat-treated high-resilience polyester cotton material and a foamed synthetic resin material. When a foamed synthetic resin material is used, for example, soft or hard urethane resin, styrene resin, ethylene resin, propylene resin, ethylene-vinyl acetate copolymer resin, or polyvinyl chloride resin can be used.

[0019] The hardened overlay mattress 10 used in the combination bedding of this embodiment is manufactured by cutting a continuously formed hardened polyester sheet to the desired size. The size of the hardened polyester sheet across the upper surface of the multiple sections of the base is, for example, greater than 140 cm square and less than 400 cm square, and more preferably, greater than 175 cm square and less than 245 cm square. The length and width are not limited to the same size, and either the length or width may be longer. Examples of sizes of this hardened overlay-type mattress 10, based on the relationship between W (width) and L (length) in Figure 2, include 140 cm x 205 cm, 160 cm x 205 cm, 180 cm x 205 cm, 200 cm x 205 cm, 240 cm x 205 cm, 280 cm x 205 cm, 300 cm x 205 cm, and 400 cm x 205 cm. Of these, the L (length) of 205 cm may be exactly the same as 200 cm, and the width may vary by a few centimeters. Furthermore, the thickness of the hardened polyester sheet having these sizes is, for example, in the range of 1 cm to 9 cm, and more preferably in the range of 1 cm to 4 cm. These sizes and thicknesses are merely examples, and other planar sizes and thicknesses can be achieved by adjusting the cutting and manufacturing methods.

[0020] FIG. 3 is a schematic diagram of users 20 and 22 sleeping on the hardening overlay-type mattress 10 of this embodiment. If the hardening overlay-type mattress 10 were not present, there is a possibility that the user 22 would become trapped in the gap 14 between a pair of, for example, single-size mattresses 12 and 16. However, by placing the hardening overlay-type mattress 10 so that it covers the top surfaces of the pair of mattresses 12 and 16, neither user 20 nor 22 will become trapped in the gap 14, allowing them to sleep in peace. Here, because the hardening overlay-type mattress 10 of this embodiment is not made of foam resin but is hardened by heat treatment, even if the gap 14 opens to a size of several centimeters, no large depression is created, and the users 20 and 22 can be stably supported on the top surface of the hardening overlay-type mattress 10. That is, the users 20, 22 can maintain their sleeping posture on the hardened overlay type mattress 10, which is harder than urethane but has sufficient cushioning, even on the gap 14, without sinking excessively, and furthermore, the hardened overlay type mattress 10 has excellent breathability due to its structure, allowing them to sleep comfortably and soundly.

[0021] The high-resilience heat-treated polyester cotton material used in the hardened overlay mattress 10 is primarily made of 100% polyester cotton. Different types of polyester cotton are blended and processed into sheets, and the resulting polyester cotton sheets are then laminated and heat-pressed together, followed by heat treatment to harden them into a hardened polyester sheet. Here, polyester cotton refers to polyester fibers processed into cotton. Known for its high elasticity, it is a mass of cotton-like fibers used in sofas, futons, cushions, stuffed toys, and more. While polyester cotton can be torn and separated, in this example, it is pressed into a hardened polyester sheet of the required thickness. The weight of the finished hardened polyester sheet is 1.2 kg / m2 per unit area due to the compression. 2 or more is desirable, typically 1.3 kg / m for cured polyester sheets.2 ~2.0kg / m 2 The weight ranges from .

[0022] The hardened polyester sheet used in the hardened overlay mattress 10 is obtained by blending different types of polyester cotton. By blending low-melting polyester cotton in particular, a mixture of melted and insoluble polyester cotton is created during heat treatment. Then, by a very short cooling process, the low-melting polyester cotton instantly solidifies, resulting in a hard, hardened polyester sheet with a high coefficient of restitution. For example, a polyester cotton sheet is obtained by uniformly blending 10-25% low-melting polyester cotton, 20-50% recycled polyester cotton, and 30-60% regular polyester cotton by weight. Low-melting polyester cotton can be made entirely from low-melting polyester fibers, or fibers with different core-sheath compositions, such as a polyester cotton core and a copolymer polyester or polyethylene sheath, can also be used. Regular polyester cotton can be, for example, 12-18 denier in diameter, while low-melting polyester cotton can be, for example, 4-6 denier in diameter.

[0023] During production, for example, regular polyester cotton, recycled polyester cotton made from recycled resources such as PET bottles, and low-melting polyester cotton are homogeneously mixed to produce a polyester cotton sheet. This sheet is folded over and fed little by little to form a laminate, where multiple polyester cotton sheets are thermocompressed together. Specifically, pressure is applied using a heated roller or similar to compress the fibers into a plate-like shape, maintaining a temperature that melts the low-melting polyester and penetrates every corner of the sheet. A relatively large heat treatment device is used for this heating process, and the polyester cotton sheet is conveyed through the heat treatment device while the low-melting polyester component within the sheet is melted by thermocompression. A blower located at the end of the heat treatment device applies cooling air to harden the molten low-melting polyester component. The compressed polyester cotton sheet hardens, reducing the volume of the sheet material.

[0024] It is possible to add a desired flame retardant or antibacterial or antifungal material to the cured polyester sheet, or to mix the desired flame retardant, antibacterial or antifungal material into the final product. The cured polyester sheet discharged in web form from the heat treatment device is cut to the required size and a cover or the like is applied to form a cured overlay mattress.

[0025] The present inventors have conducted tests to evaluate the high resilience of mattresses placed on such combination bedding. Figure 4 shows a golf ball drop test. In the golf ball drop test, a golf ball 22 was dropped from a certain height (60 cm in this test) onto the surface of the cured polyester sheet of this embodiment and onto a high-resilience polyurethane material as a comparative example, and the maximum height reached after bouncing off the surface of each sheet was measured. As shown in Table 1 below, the cured polyester sheet 18 of this embodiment bounced significantly, up to a maximum height of approximately 33 to 40 cm. In contrast, when a golf ball 22 was dropped onto a comparative high-resilience polyurethane material 20, it only bounced to a height of approximately 6 cm, demonstrating a significant difference in the coefficient of restitution.

[0026] Table 1 JPEG0007745929000001.jpg45170

[0027] The cured polyester sheet used in the cured overlay mattress of this embodiment tends to exhibit high resilience regardless of thickness. For example, if a cured polyester sheet with a thickness (height) of over 10 cm is used, when a golf ball is dropped from a height of approximately 60 cm, the ball will bounce approximately 45 cm or more. Thinner cured polyester sheets tend to have a lower bounce height. For example, if the cured polyester sheet is as thin as 1 to 2 cm, the ball may bounce approximately 25 to 30 cm. Since golf balls vary in resilience, official golf balls (weight: 45.93 grams or less, diameter: 42.67 mm or more, restitution coefficient: 0.800 or less) were used.

[0028] Next, the manufacturing process flow for the cured polyester sheet used in the cured overlay-type mattress of this embodiment will be briefly described with reference to FIG. 5. As an example, the cured polyester pillow component used in the cured overlay-type mattress of this embodiment can be manufactured using a production line equipped with a large belt conveyor. First, a craftsman engaged in manufacturing tears up the raw polyester cotton materials (regular polyester cotton, recycled polyester cotton, and low-melting-point polyester cotton) by hand and introduces them into a sheet processing machine (Step S10). This sheet processing machine thoroughly mixes the introduced polyester cotton and flattens the mixed polyester cotton (Step S12). Next, the polyester cotton sheets discharged from the sheet processing machine are stacked in an assembly line so that several sheets overlap each other (Step S14), and then the stacked sheets are compressed while being heated with a heat roll (S16). This compression process significantly reduces the thickness of the stacked polyester cotton sheets. In the manufacturing process of the cured polyester sheet of this embodiment, after compression, a heat treatment is subsequently performed (step S18), in which heat is applied to the compressed regular polyester cotton to melt and spread the low-melting point polyester cotton throughout, and finally, cooling air is applied to instantly harden the cured polyester sheet. The cured cured polyester sheet is cut using a cutting device such as a large jigsaw or laser beam (step S20), and finally, a cured overlay mattress made of a large-sized cured polyester sheet can be obtained (step S22).

[0029] As described above, the combination bedding of this embodiment uses a compressed and solidified high-resilience polyester cotton heat-treated material, and when placed on top of multiple bedding sets arranged side by side, it stabilizes the user's sleeping posture without creating any depressions, preventing health problems caused by sleeping posture such as neck pain and back pain. Furthermore, it is not limited to when sleeping, but can also prevent depressions from forming in gaps when exercising using the mattress, preventing injuries to the user.

[0030] FIG. 6 is a perspective view showing a combined bedding set using a hardened high-resilience overlay-type mattress 10. In FIG. 6, the base 62 is made of, for example, cardboard and measures 100 cm x 100 cm. When assembled, it forms a square box-shaped structure. Two such bases 62 are arranged lengthwise and widthwise to form a base, and the hardened high-resilience overlay-type mattress 10 is placed on the base, which functions as a sufficient bedding set. Cardboard does not take up much space for transport or storage, making it convenient for temporary use, such as camping or shelters. Even when sleeping on the gaps between the bases 62, the user can maintain their sleeping position without sinking excessively. Furthermore, the hardened high-resilience overlay-type mattress 10 has excellent breathability due to its structure, allowing the user to sleep comfortably.

[0031] 7 shows a combination bedding set using a hardened, high-resilience overlay mattress 30 on top of three mats 32, 34, and 36. Here, the three mats 32, 34, and 36 are all the same size, for example, 120 cm x 200 cm, and the mattress 30 is an extra-large size, for example, 370 cm x 205 cm, so as to cover the surface of the three mats lined up side by side.

[0032] 8 shows a combination bedding set using a hardened, high-resilience overlay mattress 30 on top of four mats 32, 34, 36, and 39. Here, the three mats 32, 34, 36, and 39 are all the same size, for example, 100 cm x 200 cm, and the mattress 30 is an extra-large size, for example, 420 cm x 205 cm, so as to cover the surface of the three mats lined up side by side.

[0033] 9 shows a combination bedding set using a hardened, high-resilience overlay mattress 30 on top of two mats 32, 38. Here, the two mats 32, 38 are not the same size, for example, with one mat 32 being 120 cm x 200 cm and the other mat 38 being 240 cm x 200 cm. The mattress 30 is arranged to cover the two mats 32, 38 side by side, making it an extra-large size of, for example, 370 cm x 205 cm.

[0034] 10 is an assembly diagram showing an example of a platform used for assembled bedding, with (a) showing the cardboard boxes 72 that form the platform stacked in an unfolded state, and (b) showing the cardboard boxes 72 assembled into flat rectangular boxes and arranged on the floor in a 3x3 matrix. By using foldable cardboard boxes 72 in this way, they can be stored in a space-saving manner in a warehouse or the like, and in the event of a disaster, they can be assembled and arranged as a platform on which a hardened high-resilience overlay mattress 10 (not shown) can be placed.

[0035] FIG. 11 is a perspective view showing another example of a platform used in a modular bedding set. The platform placed under the hardened, high-resilience overlay-type mattress 10 is made up of multiple liquid containers 74, each consisting of a plurality of sub-platforms. In this embodiment, a total of four rectangular liquid containers 74 are placed on the platform. The top surfaces 76 of the four liquid containers 74 form a flat surface, approximately 240 cm x 240 cm, with some gaps between them, on which the hardened, high-resilience overlay-type mattress 10 can be placed. The liquid containers 74 are made of resin, such as polypropylene resin or polyethylene resin, or polyvinyl chloride resin or other soft resins. By forming the top surfaces 76 of the liquid containers 74 from a soft material, the modular bedding set of this embodiment can also be used as a water bed. The top surfaces of the liquid containers 74 are provided with liquid inlets 78, through which liquids such as water can be poured. In the event of a disaster, the water stored in the liquid containers 74 can be used for daily life purposes such as bathing, laundry, and using the toilet.

[0036] Figure 12 shows yet another example of assembly bedding, an example of assembly bedding that partially utilizes drawer furniture. A hardened high-resilience overlay mattress 50 is held in a rolled, removable state against the wall via a holder 58, and storage furniture 54 with a drawer 56 is located below it. Normally, the hardened high-resilience overlay mattress 50 is held in a rolled state against the wall by the holder 58, but when in use, the hardened high-resilience overlay mattress 50 is pulled out and laid out on top of the storage furniture 54 and four boxes 52 that function as additional partial stands. Note that the hardened high-resilience overlay mattress 50 can be stored against the wall not only in a rolled state, but also by folding it or as a separate unit that is placed only when needed.

[0037] Figures 13 and 14 show modified examples of the hardened high-resilience overlay mattress of the present invention. Figure 13 shows a two-layer sheet, with the lower layer being a hardened polyester sheet 40 and the upper layer being a urethane sheet 42. The thickness of each resin layer can be adjusted as desired, and in cases where the hard hardened polyester sheet 40 alone is too hard, the upper layer urethane sheet 42 provides softness. Even with this configuration, the lower layer hardened polyester sheet 40 functions as a core, preventing the occurrence of depressions and the like. Figure 14 also shows the upper and lower layers being hardened polyester sheets 44, 40, with the middle layer being a urethane sheet 42. By using this three-layer structure, both sides are made of hardened polyester sheets 44, 40, and the rigidity of the sheet itself can be adjusted by the thickness of the middle layer urethane sheet 42.

[0038] Figure 15 shows an example of assembled bedding, in which multiple partial bases on which hardened high-resilience overlay mattresses 66 are placed are made up of three mats 62 and spacers 64 with a wedge-shaped cross section and sloped surfaces. By placing the spacers 64 on top of the three mats 62, the upper surface of the partial base becomes a surface that includes a slope, and by placing the hardened high-resilience overlay mattress 66 on top of that, the hardened high-resilience overlay mattress 66 takes on a shape that reflects the slope of the bottom surface, making it possible to change the shape of the hardened high-resilience overlay mattress 66 to have a shape that has a slope other than just a horizontal surface. [Explanation of symbols]

[0039] 10. Hardening overlay mattress 12, 16 Matt 14 Gap 20, 22 User 24 golf balls 26 Hardened polyester sheet 28 High-resilience polyurethane material 30 Firm High Resilience Overlay Mattress 32, 34, 36, 38, 39 Matt 40, 44 Hardened polyester sheet 42 Urethane sheet 50 Firm High Resilience Overlay Mattress 52 boxes 54 Storage furniture 56 Drawer 58 Holder 62 Matt 64 spacer 66 Hard High Resilience Overlay Mattress 72 Cardboard 74 Liquid storage container 76 Top surface 78 Inlet

Claims

1. A combination bedding set comprising a platform placed on the floor and a mattress placed on the platform, The platform is configured by arranging futons, beds or mats so that their upper surfaces are continuous, The mattress is made of a heat-treated high-resilience polyester cotton material with a weight per unit area of ​​1.3 kg / m2 to 2.0 kg / m2, the thickness of the mattress is in the range of 1 cm to 9 cm, and the mattress is formed in a size that is larger than 140 cm square and smaller than 400 cm square, covering almost the entire top surface of the base, so that no depressions are formed on the gaps in the base.

2. A combination bedding as described in claim 1, characterized in that the high-resilience polyester cotton heat-treated material is formed by blending ordinary polyester cotton and low-melting point polyester cotton and heat-treating it, and the ordinary polyester cotton uses fibers with a thickness of 12 to 18 denier, and the low-melting point polyester cotton uses fibers with a thickness of 4 to 6 denier.

3. 2. The combination bedding according to claim 1, wherein the surface resilience of the mattress is such that when a golf ball is dropped freely from a height of 60 cm, the height reached by the initial resilience is approximately 25 cm or more.

Images