Pillow core material and method for manufacturing pillow core material

Abstract

To provide a pillow core material capable of providing comfort to sleep on, and a manufacturing method of the pillow core material.SOLUTION: A pillow core material 1 related to one embodiment includes: a first part 2 on which a user's head is mounted; a second part 3 on which the user's neck is mounted; and a third part 4 on which the user's shoulders are mounted. The first part 2, the second part 3, and the third part 4 are arranged along a first direction D1 and extend in a second direction D2 crossing the first direction D1. The second part 3 has: a central part 3b positioned in the center in the second direction D2 of the second part 3; and end parts 3c positioned on both ends in the second direction D2 of the second part 3, respectively. The central part 3b with respect to the third part 4 becomes higher as it goes from the third part 4 to the first part 2. Both end parts 3c have a protrusion part 3g protruding to the third part 4. In the state that no external force is applied, a gap is formed between a lower surface of the protrusion part 3g and an upper surface of the third part 4.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] SUMMARY The present disclosure relates to a pillow core on which a user's head, neck, and shoulders rest, and a method for making the pillow core. [Background technology]

[0002] Registered Utility Model No. 3217333 describes a mattress-integrated pillow in which the mattress and pillow are molded as one unit. The pillow has a convex portion for supporting the user's neck when lying on their back, and a concave portion located on the opposite side of the mattress, sandwiching the convex portion. A raised portion is formed in the vertical center of the mattress.

[0003] In plan view, the mat is trapezoidal, and the pillow has a rod-shaped convex portion. The convex portion has both side portions and a central portion, and the height of the both side portions is higher than the height of the central portion. In this integrated mattress pillow, the pillow, which has a convex portion with a central portion and both side portions higher than the central portion, and the mat are molded as a single unit. The integrated mattress pillow is made of a mixed material of gel and urethane, and its elasticity provides flexibility and resilience. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Registered Utility Model No. 3217333 Summary of the Invention [Problem to be solved by the invention]

[0005] The aforementioned mattress-integrated pillow is manufactured by integral molding using a foam resin material such as urethane. Because the mattress-integrated pillow is manufactured by integral molding, it can be produced efficiently while keeping costs down. The mattress-integrated pillow has a smooth shape with no noticeable irregularities except for the convex portions. This makes it easy to remove from the mold after the urethane material is foamed. However, in order to fit the pillow to the user's body, a complex structure may be required. In particular, when a user sleeps on their side, a smooth-shaped pillow may create a gap between the pillow and the user's neck. This may cause neck pain when sleeping on their side, leaving room for improvement in terms of comfort when sleeping on your side.

[0006] An object of the present disclosure is to provide a pillow core material that can provide a more comfortable sleeping experience, and a method for manufacturing a pillow core material. [Means for solving the problem]

[0007] The pillow core according to the present disclosure includes a first portion on which the user's head rests, a second portion on which the user's neck rests, and a third portion on which the user's shoulders rest. Pillow core material The first, second and third parts are aligned in a first direction in a plan view and extend in a second direction intersecting the first direction. The second part has a central part located in the center of the second part in the second direction and two end parts located at both ends of the second part in the second direction. The height of the central part relative to the third part increases from the third part toward the first part. The two end parts have protrusions that protrude toward the third part. When no external force is applied, a gap is formed between the lower surface of the protrusion and the upper surface of the third part. The protruding portion has an upper surface facing vertically upward, a side surface facing the legs of a user lying on the pillow core, and a lower surface extending obliquely downward from the side surface, and when viewed along the second direction, the upper surface, side surface, lower surface of the protruding portion, and the upper surface of the third portion form a Z-shape. .

[0008] This pillow core has a first portion on which the head is placed, a second portion on which the neck is placed, and a third portion on which the shoulders are placed, all aligned along a first direction in a plan view. The first, second, and third portions each extend in a second direction intersecting the first direction in a plan view. The second portion on which the neck is placed has a central portion located in the center of the second direction and two end portions located at both ends of the second direction. The height of the central portion increases from the third portion to the first portion. Therefore, when the user is sleeping on their back, the central portion is located under the neck, and the height of the central portion increases from the back to the head. Therefore, the height of the central portion is set to fit the shape of the user's neck when sleeping on their back, allowing the central portion to gently support the neck when sleeping on their back. As a result, sleeping on one's back is comfortable. Both end portions of the second portion have protrusions that protrude toward the third portion, and gaps are formed between the upper surface of the third portion and the lower surface of the protrusions. Therefore, when the user sleeps on their side, their neck rests on the protruding parts on both sides, and the protruding parts lower and reduce the gap. Therefore, when the user's neck rests on the protruding parts while sleeping on their side, the protruding parts lower and flexibly deform, making it less likely that a gap will form between the protruding parts and the neck. This reduces neck pain when sleeping on your side, making sleeping more comfortable when sleeping on your side.

[0009] The lower surface of the protrusion may be inclined relative to the upper surface of the third section. The angle of inclination of the lower surface relative to the upper surface may be greater than 0 degrees and less than 90 degrees. In this case, the lower surface of the protrusion extends diagonally upward from the upper surface of the third section, making it easier for the protrusion to deform when the neck is placed on it. This allows for a more comfortable side-sleeping experience for the user.

[0010] The first portion may have a through-hole penetrating the first portion in a third direction intersecting both the first and second directions. In this case, the first portion on which the head rests has the through-hole, improving the breathability of the first portion. This provides the user with a more comfortable sleeping experience.

[0011] The method for manufacturing a pillow core according to the present disclosure is a method for manufacturing the aforementioned pillow core using a mold that is rectangular in plan view. The mold has a recess located on one side of the mold in the short direction in plan view, and a protrusion that forms an acute angle with the bottom surface of the recess. The protrusions are provided on both one and the other side of the mold in the long direction in plan view. A gap is formed between the bottom surface of the recess and the underside of the protrusion. The method for manufacturing a pillow core includes the steps of pouring liquid urethane foam into the recess and the protrusion, foam-molding the urethane foam inside the mold to form protrusions of the pillow core in the gap, and removing the urethane foam foamed inside the mold from the mold.

[0012] This method of manufacturing a pillow core uses a mold having a recess located on one side of the mold in the short direction in a plan view and a protrusion that forms an acute angle with the bottom of the recess. The protrusions are provided on both sides in the longitudinal direction, and a gap is formed between the bottom of the recess and the underside of the protrusion. In this manufacturing method, liquid urethane foam is poured into the recess and protrusion of the mold, filling the gap. Then, when the urethane foam is foam-molded inside the mold, the aforementioned protrusion of the pillow core is formed in the gap. Therefore, in this manufacturing method, the aforementioned protrusion of the pillow core can be formed by urethane molding, making it possible to manufacture a pillow core from urethane foam that provides a comfortable sleep. [Effects of the Invention]

[0013] According to the present disclosure, a more comfortable sleeping experience can be provided. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a perspective view of a pillow core material according to an embodiment, seen from above. [Figure 2] FIG. 2 is a perspective view of the pillow core material according to the embodiment, seen from below. [Figure 3] 2 is a perspective view showing a first portion and a second portion of the pillow core of FIG. 1. FIG. [Figure 4] 2 is a perspective view showing the protruding portions on both sides and the central portion of the second portion of the pillow core of FIG. 1. FIG. [Figure 5] FIG. 5 is a perspective view showing the central part of FIG. [Figure 6] FIG. 2 is a perspective view showing a mold used in a method for manufacturing a pillow core according to an embodiment. [Figure 7] FIG. 7 is a perspective view showing a state in which liquid urethane foam is poured into the mold of FIG. 6. [Figure 8] FIG. 8 is a perspective view showing the mold of FIG. 7 in a closed state. [Figure 9] FIG. 9 is a perspective view showing the urethane foam foamed inside the mold of FIG. 8. [Figure 10] FIG. 10 is a perspective view showing the state in which the urethane foam of FIG. 9 is being removed from the mold. [Figure 11] FIG. 10 is a perspective view showing the state in which the urethane foam of FIG. 9 is being removed from the mold. [Figure 12] 1 is a diagram schematically illustrating a state in which a user is lying on his / her back on the pillow core according to an embodiment. FIG. [Figure 13] 1 is a diagram showing a state in which a user is lying on his / her side on the pillow core material according to an embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, embodiments of the pillow core material and the method for manufacturing the pillow core material according to the present disclosure will be described with reference to the drawings. In the description of the drawings, the same or corresponding elements are given the same reference numerals, and duplicated explanations will be omitted as appropriate. In addition, the drawings may be partially simplified or exaggerated for ease of understanding, and the dimensional ratios, angles, etc. are not limited to those shown in the drawings.

[0016] Fig. 1 is a perspective view of a pillow core 1 according to this embodiment, seen from above. Fig. 2 is a perspective view of the pillow core 1, seen from below. As shown in Figs. 1 and 2, the pillow core 1 comprises a first portion 2 on which the head M1 of a user M (see Figs. 12 and 13) is placed, a second portion 3 on which the neck M2 of the user M is placed, a third portion 4 on which the shoulders M3 of the user M are placed, and a fourth portion 5 on which the back of the user M is placed.

[0017] The pillow core 1 is used, for example, housed in a fabric cover. For example, the pillow core 1 is a pillow core on which the portion of the body of the user M from the head M1 to the back is placed, and is longer in the direction in which the body extends than a normal pillow. The pillow core 1 has a lower surface 1f on the opposite side to the surface (upper surface) on which the first portion 2, the second portion 3, the third portion 4, and the fourth portion 5 are provided. The lower surface 1f is, for example, flat.

[0018] In a plan view, the first portion 2, the second portion 3, the third portion 4, and the fourth portion 5 are arranged in this order along a first direction D1. Each of the first portion 2, the second portion 3, the third portion 4, and the fourth portion 5 extends along a second direction D2 that intersects with the first direction D1. For example, the second direction D2 is a direction perpendicular to the first direction D1.

[0019] The pillow core 1 has a pair of first sides 1b extending in the first direction D1 and aligned along the second direction D2, a second side 1c extending along the second direction D2 at one end of the pillow core 1 in the first direction D1, and a third side 1d extending along the second direction D2 at the other end of the pillow core 1 in the first direction D1. Each of the pair of first sides 1b is located at an end of the third portion 4 and the fourth portion 5 in the second direction D2. The second side 1c extends along the second direction D2 at an end of the first portion 2 opposite the second portion 3. The third side 1d extends along the second direction D2 at an end of the fourth portion 5 opposite the third portion 4.

[0020] If the height direction of the pillow core 1 is the third direction D3, for example, the length (height) of the first portion 2 in the third direction D3 and the length of the second portion 3 in the third direction D3 are longer than the lengths of the third portions 4 and 5 in the third direction D3. In the following description, a state in which the length in the third direction D3 is long may be referred to as "tall" or "thick," and a state in which the length in the third direction D3 is short may be referred to as "low" or "thin." The third direction D3 indicates a direction that intersects both the first direction D1 and the second direction D2, and, as an example, is perpendicular to both the first direction D1 and the second direction D2. For example, the shape of the pillow core 1 when viewed along the third direction D3 (in a plan view) is rectangular.

[0021] The pillow core 1 is made of a flexible material. In this disclosure, "flexible material" refers to a material that is soft enough to deform when placed on it. The "flexible material" includes, for example, at least one of elastic foam, fibrous material, flexible material, and soft material.

[0022] The pillow core 1 is made of, for example, an elastic foam, and as an example, the entire pillow core 1 is made of urethane foam. In this case, the pillow core 1 is formed by urethane molding. When the pillow core 1 is made of urethane foam and formed by urethane molding, the pillow core 1 made of a flexible material can be easily manufactured.

[0023] The first portion 2 has a first protrusion 2b located at the end of the pillow core 1 in the first direction D1, a second protrusion 2c extending along the second direction D2 at a position adjacent to the second portion 3, and a recess 2d located between the first protrusion 2b and the second protrusion 2c. Fig. 3 is a perspective view of the first portion 2 seen from the second direction D2. As shown in Figs. 1 to 3, the first portion 2 has a plurality of through holes 2f penetrating the first portion 2 in the third direction D3.

[0024] The first protrusion 2b has a first inclined portion 2g located on the opposite side to the recessed portion 2d of the first portion 2, a second inclined portion 2h extending from the recessed portion 2d of the first portion 2 toward the first inclined portion 2g, and an apex 2j extending in the second direction D2 between the first inclined portion 2g and the second inclined portion 2h. For example, the first inclined portion 2g, the second inclined portion 2h, and the apex 2j all extend along the second direction D2.

[0025] For example, the second protrusion 2c and the recess 2d both extend along the second direction D2. The second protrusion 2c has a third inclined portion 2k that becomes higher as it moves away from the recess 2d in the first direction D1. The first portion 2 has, for example, a pair of second protrusions 2c aligned along the second direction D2, with a depression 2p formed between the pair of second protrusions 2c. The first protrusion 2b, the recess 2d, and the second protrusion 2c extend in the first direction D1 and present a wave-shaped configuration that meanders in the third direction D3. The first inclined portion 2g, the peak 2j, the second inclined portion 2h, the recess 2d, and the third inclined portion 2k are aligned in this order along the first direction D1.

[0026] The first portion 2 has, for example, a plurality of through holes 2f aligned along each of the first direction D1 and the second direction D2. That is, the through holes 2f are arranged in a lattice pattern in the first portion 2. As an example, four through holes 2f are aligned along the first direction D1, and seven through holes 2f are aligned along the second direction D2.

[0027] For example, through holes 2f are formed in each of the first convex portion 2b, the second convex portion 2c, and the recessed portion 2d. As a specific example, a plurality of through holes 2f are formed in each of the second inclined portion 2h, the recessed portion 2d, and the second convex portion 2c so as to be aligned along the second direction D2. By arranging the through holes 2f in this manner, the breathability of the first portion 2 is improved, and therefore, it is possible to prevent the head M1 placed on the first portion 2 from becoming stuffy.

[0028] The second portion 3 is provided on an extension of the second protrusion 2c in the first direction D1. The second portion 3 has a central portion 3b located in the center of the second portion 3 in the second direction D2, and end portions 3c located on both ends of the second portion 3 in the second direction D2. Figure 4 is a perspective view of the second portion 3 as seen from the second direction D2.

[0029] 1, 3, and 4, the height of the central portion 3b relative to the third portion 4 increases from the third portion 4 toward the first portion 2. The central portion 3b has a first curved surface 3d extending from the depression 2p of the first portion 2 toward the third portion 4, and a second curved surface 3f extending from the first curved surface 3d to the third portion 4.

[0030] 5 is an enlarged perspective view of the central portion 3b. As shown in FIGS. 4 and 5, for example, the first curved surface 3d is curved so as to bulge outward (upward) from the central portion 3b, and the second curved surface 3f is curved so as to recess inward (downward) from the central portion 3b. As an example, the shapes of the first curved surface 3d and the second curved surface 3f when viewed from the second direction D2 are arc-shaped. However, the shape of the central portion 3b is not limited to the above example.

[0031] Both end portions 3c have protruding portions 3g that protrude toward the third portion 4. For example, the protruding portions 3g have an upper surface 3k that faces vertically upward, a side surface 3h that faces the legs of a user lying on the pillow core 1, and a lower surface 3j that extends diagonally downward from the side surface 3h. The side surface 3h is, for example, flat. However, the side surface 3h does not have to be flat, and may be a curved surface that protrudes toward the legs of a user lying on the pillow core 1.

[0032] A gap S is formed between the lower surface 3j of the protrusion 3g and the upper surface 4b of the third portion 4. The lower surface 3j extends obliquely upward from the end of the upper surface 4b on the first portion 2 side toward the fourth portion 5. The inclination angle θ of the lower surface 3j with respect to the upper surface 4b is, for example, greater than 0° and less than 90°. That is, the inclination angle θ is an acute angle. The inclination angle θ may be 10° or more and 80° or less, 20° or more and 70° or less, or 30° or more and 60° or less. The side surface 3h extends upward from the upper end of the lower surface 3j, and the upper surface 3k extends from the upper end of the side surface 3h toward the first portion 2.

[0033] When viewed in the second direction D2, the protrusion 3g (lower surface 3j) and the third portion 4 are Z-shaped. That is, when viewed in the second direction D2, the upper surface 3k, side surface 3h, lower surface 3j of the protrusion 3g, and upper surface 4b of the third portion 4 all have a Z-shape. A gap S is formed between the lower surface 3j of the protrusion 3g and the upper surface 4b of the third portion 4 at least when no external force is applied to the protrusion 3g.

[0034] The third portion 4 has side portions 4c extending in the first direction D1 and the second direction D2 on both sides of the central portion 3b in the second direction D2. The side portions 4c are portions on which the shoulders M3 of the user M lying on their side are placed. The fourth portion 5 is located on the opposite side of the second portion 3 from the third portion 4, and extends in the first direction D1 and the second direction D2.

[0035] For example, the third portion 4 and the fourth portion 5 are sheet-shaped and extend in the first direction D1 and the second direction D2, and have a thickness in the third direction D3. As an example, the thickness of the third portion 4 increases from the fourth portion 5 toward the second portion 3, and the thickness of the fourth portion 5 increases toward the third portion 4.

[0036] Next, a method for manufacturing the pillow core according to this embodiment will be described. An example of steps in the manufacturing method for manufacturing the pillow core 1 described above will be described below. As shown in Fig. 6, the pillow core 1 is manufactured using, for example, a mold 10. First, the configuration of the mold 10 used when manufacturing the pillow core 1 will be described.

[0037] The mold 10 has a rectangular shape in a plan view. The mold 10 includes, for example, a main body 15 having a concave resin injection portion 11, and a lid portion 12 that closes the resin injection portion 11. The mold 10 further includes a hinge mechanism 13 that opens and closes the lid portion 12 relative to the main body 15, and a fixing portion 14 that fixes the lid portion 12, which closes the resin injection portion 11 of the main body 15, to the main body 15. The hinge mechanism 13 extends along the longitudinal direction A1 at the end of the main body 15 in the short-side direction A2 in a plan view. The lid portion 12 is rotatable around the hinge mechanism 13, which extends along the longitudinal direction A1, as a central axis.

[0038] The main body 15 has, for example, a rectangular box shape extending in the longitudinal direction A1, lateral direction A2, and height direction A3 of the mold 10. The resin injection section 11 is recessed, for example, from the upper surface 15b of the main body 15. The resin injection section 11 has a recess 11b located on one side in the lateral direction A2 in a plan view, and a protrusion 11d that forms an acute angle with the bottom surface 11c of the recess 11b. The protrusion 11d protrudes toward the recess 11b at the end of the recess 11b in the lateral direction A2. In a plan view, the recess 11b extends in both the longitudinal direction A1 and the lateral direction A2.

[0039] The resin injection portion 11 has, for example, a protruding portion 11f that protrudes from the recessed portion 11b and extends along the longitudinal direction A1. The protruding portion 11f corresponds to the portion that forms the recessed portion 2d of the first portion 2. The protruding portion 11d corresponds to the portion that forms the gap S between the protruding portion 3g and the third portion 4.

[0040] The convex portions 11d are provided on both sides of the mold 10 in the longitudinal direction A1 in a plan view. A gap 11h is formed between the lower surface 11g of the convex portion 11d and the bottom surface 11c of the recessed portion 11b. The gap 11h corresponds to the portion that forms the protrusion 3g. The resin injection portion 11 has an inclined portion 11j that is recessed between the pair of convex portions 11d.

[0041] The inclined portion 11j corresponds to the surfaces that form the first curved surface 3d and the second curved surface 3f of the central portion 3b. The resin injection portion 11 has an upper surface portion 11k on the other side in the short-side direction A2 in a plan view (the side opposite to the recess 11b). The height of the upper surface portion 11k decreases toward the recess 11b. The upper surface portion 11k corresponds to the portion that forms the third portion 4 and the fourth portion 5.

[0042] Next, an example of a process for manufacturing the pillow core 1 will be described. First, a release agent is applied to the recess 11b, protrusion 11d, protrusion 11f, lower surface 11g, inclined portion 11j, and upper surface 11k of the resin injection portion 11. This makes it easier to peel the urethane foam H from the mold 10 after foam molding. Then, liquid urethane foam H, which will be the base of the pillow core 1, is poured into the recess 11b of the resin injection portion 11 of the mold 10.

[0043] 6 and 7, urethane foam H is poured into the recessed portion 11b and the protruding portion 11d of the resin injection portion 11 (a step of pouring urethane foam). Then, the urethane foam H is poured into the bottom surface 11c, the protruding portion 11f, the lower surface 11g, the gap 11h, the inclined portion 11j, and the upper surface portion 11k.

[0044] After the urethane foam H has been poured into the resin injection section 11 as described above, the lid section 12 is rotated via the hinge mechanism 13 to seal the resin injection section 11 with the lid section 12 as shown in Fig. 8 (step of sealing the resin injection section). Then, the urethane foam H is foamed inside the main body section 15 and the lid section 12. At this time, the urethane foam H is foam-molded inside the mold 10, and the protruding section 3g of the pillow core 1 is formed in the gap 11h of the mold 10 (step of forming the protruding section).

[0045] After the foaming of the urethane foam H, as shown in Fig. 9, the lid 12 is opened from the main body 15, and the molded urethane foam H is removed from the resin injection section 11 (step of removing the molded urethane foam). At this time, as shown in Figs. 10 and 11, for example, the urethane foam H is lifted from the side opposite the recess 11b in the short direction A2 of the mold 10, and then the urethane foam H is lifted from the side of the recess 11b in the short direction A2 of the mold 10 to remove it. In this case, the protrusion 3g is prevented from getting caught in the gap 11h, so the urethane foam H can be smoothly removed from the mold 10. Then, after forming a plurality of through holes 2f in the urethane foam H removed from the mold 10 (step of forming through holes), the series of steps in the method for manufacturing the pillow core 1 is completed.

[0046] Next, the effects obtained from the pillow core 1 and the manufacturing method of the pillow core 1 according to this embodiment will be described. As shown in Fig. 1, the pillow core 1 has a first portion 2 on which the head M1 is placed, a second portion 3 on which the neck M2 is placed, and a third portion 4 on which the shoulders M3 are placed, which are aligned along a first direction D1 in a plan view. The first portion 2, second portion 3, and third portion 4 each extend in a second direction D2 that intersects with the first direction D1 in a plan view. The second portion 3 on which the neck M2 is placed has a central portion 3b located in the center of the second direction D2 and two end portions 3c located on either end of the second direction D2. The height of the central portion 3b increases from the third portion 4 toward the first portion 2.

[0047] 12 and 13 are diagrams schematically showing a state in which a user M is using the pillow core material 1. In the pillow core material 1 according to this embodiment, as shown in FIGS. 1 and 12, when the user M is sleeping on his / her back, the central portion 3b is located under the neck M2, and the height of the central portion 3b increases from the back toward the head M1. Therefore, the height of the central portion 3b is set to fit the shape of the neck M2 of the user M when sleeping on his / her back, so that the neck M2 can be gently supported by the central portion 3b when sleeping on his / her back. As a result, the user M can sleep comfortably when sleeping on his / her back.

[0048] As shown in Figures 1, 4, and 5, both end portions 3c of the second portion 3 have protrusions 3g that protrude toward the third portion 4, and a gap S is formed between the upper surface 4b of the third portion 4 and the lower surface 3j of the protrusions 3g. Therefore, when the user M sleeps on his / her side, the neck M2 rests on the protrusions 3g of both end portions 3c, and the protrusions 3g lower, reducing the gap S. Therefore, as shown in Figure 13, when the neck M2 of the user M sleeping on his / her side is placed on the protrusions 3g, the protrusions 3g lower and flexibly deform, making it less likely that a gap will form between the protrusions 3g and the neck M2. This reduces pain in the neck M2 when sleeping on his / her side, and improves the comfort of the user M when sleeping on his / her side.

[0049] 1, 4, and 5, in this embodiment, the lower surface 3j of the protrusion 3g is inclined relative to the upper surface 4b of the third portion 4. The inclination angle θ of the lower surface 3j relative to the upper surface 4b is greater than 0 degrees and less than 90 degrees. Therefore, the lower surface 3j of the protrusion 3g extends diagonally upward from the upper surface 4b of the third portion 4, which makes it easier for the protrusion 3g to deform when the neck M2 is placed on it. This allows the user M to sleep more comfortably on their side.

[0050] In this embodiment, the first portion 2 has a through-hole 2f that penetrates the first portion 2 in a third direction D3 that intersects both the first direction D1 and the second direction D2. Therefore, the first portion 2 on which the head M1 is placed has the through-hole 2f, which improves the breathability of the first portion 2. Therefore, the user M can be provided with a more comfortable sleeping experience.

[0051] In the manufacturing method of the pillow core 1 according to this embodiment, as shown in Fig. 6, a mold 10 is used that has a recess 11b located on one side of the mold 10 in the short-side direction A2 in a plan view, and a protrusion 11d that forms an acute angle with the bottom surface 11c of the recess 11b. The protrusion 11d is provided on each of one side and the other side in the longitudinal direction A1, and a gap 11h is formed between the bottom surface 11c of the recess 11b and the lower surface 11g of the protrusion 11d.

[0052] In the manufacturing method of the pillow core 1 according to this embodiment, when liquid urethane foam H is poured into the recessed portions 11b and protruding portions 11d of the mold 10, the urethane foam H fills the gaps 11h. Then, when the urethane foam H is foam-molded inside the mold 10, the aforementioned protruding portions 3g of the pillow core 1 are formed in the gaps 11h. Therefore, in this manufacturing method, the aforementioned protruding portions 3g of the pillow core 1 can be formed by urethane molding, so that a pillow core 1 that provides good sleeping comfort can be manufactured from the urethane foam H.

[0053] The above describes embodiments of the pillow core and the method for manufacturing the pillow core according to the present disclosure. However, the present disclosure is not limited to the above-described embodiments, and may be modified or applied to other things without departing from the spirit of the claims. In other words, the shape, size, number, material, and arrangement of each part of the pillow core, as well as the content and order of the steps in the method for manufacturing the pillow core, may be modified as appropriate without departing from the spirit of the present disclosure.

[0054] For example, in the above-described embodiment, an example was described in which four through holes 2f are arranged along the first direction D1 and seven through holes 2f are arranged along the second direction D2. However, the number, size, and arrangement of the through holes in the first portion are not limited to the above example. Furthermore, the pillow core may have a first portion that does not have any through holes. In the above-described embodiment, the pillow core 1 is described as having a first portion 2, a second portion 3, a third portion 4, and a fourth portion 5. However, the pillow core according to the present disclosure may not have a fourth portion 5 on which the user's back rests.

[0055] In the above-described embodiment, an example was described in which a pillow core 1 was manufactured using a mold 10 that was rectangular in plan view. However, the shape and size of the mold for manufacturing the pillow core 1 are not limited to those in the above-described embodiment, and the configuration of the mold can be changed as appropriate. Also, in the above-described embodiment, a pillow core 1 was described that included a second portion 3 having a protruding portion 3g that was Z-shaped when viewed along the second direction D2. However, the shape of the protruding portion when viewed along the second direction may be a shape other than Z-shaped and can be changed as appropriate. [Explanation of symbols]

[0056] 1... Pillow core material, 1b... first side, 1c... second side, 1d... third side, 2... first part, 2b... first convex part, 2c... second convex part, 2d... recessed part, 2f... through hole, 2g... first inclined part, 2h... second inclined part, 2j... top, 2k... third inclined part, 2 p... depression, 3... second part, 3b... central part, 3c... both ends, 3d... first curved surface, 3f... second curved surface, 3g... protrusion, 3h... side surface, 3j... bottom surface, 3k... top surface, 4... third part, 4b... top surface, 4c... both sides, 5... fourth part, 10... Mold, 11...Resin injection part, 11b...Concave part, 11c...Bottom surface, 11d...Convex part, 11f...Protrusion part, 11g...Bottom face, 11h...Gap, 11j...Slope part, 11k...Top part, 12...Cover part, 13...Hinge mechanism, 14...Fixing part, 15...Body part , 15b...Top surface, A1...Longitudinal direction, A2...Short direction, A3...Height direction, D1...First direction, D2...Second direction, D3...Third direction, H...Urethane foam, M...User, M1...Head, M2...Neck, M3...Shoulder, S...Gap, θ...Inclination angle.

Claims

1. a first portion on which the user's head rests; a second portion on which the user's neck rests; a third portion on which the user's shoulders rest; A pillow core material comprising: the first portion, the second portion, and the third portion are aligned along a first direction and extend in a second direction intersecting the first direction in a plan view; the second portion has a central portion located at a center of the second portion in the second direction and two end portions located at both ends of the second portion in the second direction, a height of the central portion relative to the third portion increases from the third portion toward the first portion, The two end portions have protrusions that protrude toward the third portion, a gap is formed between a lower surface of the protruding portion and an upper surface of the third portion when no external force is applied, The protrusion has an upper surface facing vertically upward, a side surface facing the legs of a user lying on the pillow core, and a lower surface extending obliquely downward from the side surface, When viewed along the second direction, the upper surface, the side surface, the lower surface of the protrusion, and the upper surface of the third portion form a Z-shape. Pillow core material.

2. a lower surface of the protrusion is inclined relative to an upper surface of the third portion, the inclination angle of the lower surface relative to the upper surface is greater than 0 degrees and less than 90 degrees; The pillow core material according to claim 1.

3. the first portion has a through hole penetrating the first portion in a third direction intersecting both the first direction and the second direction; The pillow core material according to claim 1 or 2.

4. A method for manufacturing a pillow core material according to any one of claims 1 to 3, using a mold having a rectangular shape in a plan view, the mold has a recess located on one side in a short-side direction of the mold in a plan view, and a protrusion forming an acute angle with a bottom surface of the recess, the protrusion being provided on each of one side and the other side in a long-side direction of the mold in a plan view, and a gap being formed between the bottom surface of the recess and a lower surface of the protrusion, pouring liquid urethane foam into the recessed and protruding portions; a step of foaming the urethane foam inside the mold to form the protruding portion of the pillow core material in the gap; a step of removing the urethane foam foamed in the mold from the mold; A method for manufacturing a pillow core material comprising:

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