Method for manufacturing a hardened overlay mattress

Abstract

To provide a mattress which is used together with a plurality of mats arranged by alignment and has a structure capable of ensuring sufficient sleeping.SOLUTION: A cured overlay type mattress is to be placed on upper surfaces of a plurality of mats arranged by alignment. The cured overlay type mattress is obtained by: compounding a plurality of different kinds of polyester cottons and performing processing the cottons to have a sheet shape; press-bonding polyester cotton sheets processed into a sheet shape after lamination; and then processing a cured polyester sheet cured by applying a heat-treatment to be in a size over the upper surfaces of the mats arranged by alignment.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention provides a hardening overlay type mattress that can be placed on top of multiple bedding pieces arranged side by side. Manufacturing method Regarding. [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 if a component such as a gap pad is placed, there is a risk that small children's hands or feet may get caught in the edge of the gap pad, resulting in sleeping positions that are harmful to their health. Also, if the gap pad is made of a material such as urethane foam, it may be too soft and create depressions that reflect the gap between two futons or mattresses, and such depressions can easily cause health problems such as neck pain and back pain caused by sleeping posture.

[0006] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a mattress that is used with a plurality of bedding items arranged side by side and has a structure that ensures a good night's sleep. [Means for solving the problem]

[0007] In order to solve the above technical problems, the hardening overlay mattress of the present invention Manufacturing method The hardening overlay type mattress is placed on the top surface of a plurality of beddings arranged side by side. Manufacturing method The method is characterized in that recycled polyester cotton and two types of polyester cotton with different melting points are blended and processed into sheets, the polyester cotton sheets processed into sheets are stacked and heat-pressed together, and then heat-treated and cooled to harden, thereby continuously forming hardened polyester sheets, which are then cut to a size that covers the top surfaces of the plurality of bedding sets.

[0008] The hardened overlay mattress manufactured by such a process can be formed by cutting the hardened polyester sheet to the desired size. For example, the size of the hardened polyester sheet covering the top surface of the plurality of bedding pieces is greater than 140 cm square and less than 300 cm square, and more preferably, greater than 175 cm square and less than 245 cm square. The length and width are not limited to being the same size, and either the length or width may be longer.

[0009] In the hardened overlay mattress according to a preferred embodiment of the present invention, the thickness of the hardened polyester sheet can be in the range of 1 cm to 4 cm, more preferably in the range of 1.5 cm to 3.3 cm. In the hardened overlay mattress according to one example of the present invention, the weight per unit area of ​​the hardened polyester sheet is 1.2 kg / m. 2 or more, more preferably 1.5 kg / m 2 Or more.

[0010] Furthermore, in a preferred embodiment of the hardened overlay mattress of the present invention, the surface resilience of the hardened polyester sheet is characterized in that, for example, 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, more preferably approximately 28 cm or more. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic perspective view illustrating the use of a stiffening overlay mattress according to one embodiment of the present invention on a pair of mattresses. [Figure 2] 1 is a schematic top view of a hardening overlay mattress according to an embodiment of the present invention. FIG. [Figure 3] 1 is a perspective view showing a state in which a hardening overlay type mattress according to an embodiment of the present invention is used. FIG. [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 hardened polyester sheet used in a hardened overlay-type mattress according to an embodiment of the present invention. [Figure 6] 1 is a schematic perspective view of a combination bedding according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] An embodiment of the hardening overlay-type mattress of the present invention will be described with reference to the drawings. Fig. 1 is a schematic perspective view for explaining a hardening overlay-type mattress 10, which shows a pair of mats 12 and 16 arranged side by side as bedding, with a small gap 14 between these mats 12 and 16. The upper surfaces of these mats 12 and 16 allow sleepers to lie in any position, and the hardening overlay-type mattress 10 is placed to cover these upper surfaces, making it possible to use the entire mattress as a large-sized bed, with the hardening overlay-type mattress 10 and mats 12 and 16 constituting a single combination of bedding.

[0013] The term "mattress" as used herein is broadly understood and may be used alone or may include, for example, quilting or a covering. The hardened overlay-type mattress 10 can also be used with a sheet or towel placed over it. The term also broadly refers to a pair of bedding placed under the hardened overlay-type mattress 10, and includes not only futons and single-size beds, but also sofas, cushions, and various other materials such as wooden boxes, cardboard boxes, mandarin orange boxes, and liquor bottle crates, as well as combinations thereof. One of the bedding pieces may be fixed to a building or other structure. Furthermore, the term is not necessarily limited to bedding 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-type mattresses are not necessarily limited to those used permanently, and can also be used temporarily.

[0014] The cured polyester sheet used in the cured overlay-type mattress 10 is manufactured by cutting a continuously cured polyester sheet to the desired size. The size of the cured polyester sheet covering the upper surface of the multiple bedding units is greater than 140 cm square and less than 300 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; either the length or width may be longer. Examples of sizes of such a cured overlay-type mattress 10, based on the relationship between W (width) and L (length) in FIG. 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, and 300 cm x 205 cm. The thickness of the cured polyester sheet having these sizes is, for example, in the range of 1 cm to 4 cm. These sizes and thicknesses are merely examples, and it goes without saying that other planar sizes and thicknesses can be obtained by adjusting the cutting method and manufacturing method.

[0015] 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.

[0016] The material of the hardened polyester sheet used in the hardened overlay mattress 10 is primarily made of 100% polyester cotton. Here, polyester cotton is polyester fiber processed into cotton, and is a mass of cotton-like fibers known for its high elasticity, used in sofas, futons, cushions, stuffed toys, etc. Polyester cotton can be torn and separated, but in this embodiment, it is pressed into a sheet of the required thickness to create a hardened polyester sheet. The weight of the completed hardened polyester sheet is 1.2 kg / m2 because it is compressed. 2 or more is desirable, typically 1.3 kg / m for cured polyester sheets. 2 ~2.0kg / m 2 The weight ranges from .

[0017] 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.

[0018] 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.

[0019] 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.

[0020] The present inventors have conducted tests on the high resilience performance of such cured polyester sheets. 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 free onto the high-resilience polyurethane material 20 as a comparative example, it only bounced to a height of approximately 6 cm, demonstrating a significant difference in the coefficient of restitution.

[0021] Table 1 JPEG0007797041000001.jpg45170

[0022] 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 about 60 cm, the ball will bounce about 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 2 cm, the ball may bounce about 30 cm. Since golf balls vary in resilience, official balls (weight: 45.93 grams or less, diameter: 42.67 mm or more, restitution coefficient: 0.800 or less) were used.

[0023] 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).

[0024] 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.

[0025] As described above, the hardened overlay mattress of this embodiment uses a compressed and hardened hardened polyester sheet, which is not as soft as typical foamed urethane resin and is a firm, highly resilient sheet. Therefore, when placed on top of multiple bedding items 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 the occurrence of depressions in gaps when exercising using the mattress, preventing injuries to the user. [Explanation of symbols]

[0026] 10. Hardening overlay mattress 12, 16 Matt 14 Gap 20, 22 User 24 golf balls 26 Hardened polyester sheet 28 High-resilience polyurethane material

Claims

1. A method for manufacturing a hardening overlay type mattress that is placed on top of multiple beddings arranged side by side, comprising: A method for manufacturing a hardened overlay mattress, characterized in that recycled polyester cotton and two types of polyester cotton with different melting points are blended and processed into sheets, the polyester cotton sheets processed into sheets are laminated and thermocompressed together, and then heat-treated and cooled to harden, thereby continuously forming hardened polyester sheets, which are then cut to a size that covers the upper surfaces of the multiple beddings.

2. 2. A method for manufacturing a hardened overlay mattress according to claim 1, wherein the size of the hardened polyester sheet covering the upper surface of the plurality of beddings is greater than 140 cm square and less than 300 cm square.

3. 2. The method of claim 1, wherein the thickness of the stiffening polyester sheet is in the range of 1 cm to 4 cm.

4. 2. A method for manufacturing a hardened overlay mattress according to claim 1, wherein the surface resilience of the hardened polyester sheet 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.

5. 2. The method for manufacturing a hardened overlay mattress according to claim 1, wherein the hardened polyester sheet has a weight per unit area of ​​1.2 kg / m ２ or more.

6. 2. A method for manufacturing a hardening overlay mattress according to claim 1, wherein the hardening overlay mattress is combined with a platform having a flat upper surface and used as part of a combination bedding set.

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