mattress

Abstract

To provide a mattress that can improve work efficiency at the time of dismantlement.SOLUTION: A mattress includes: a spring unit including a plurality of coils; and a wall member for enclosing the spring unit. The spring unit includes: a lower part including a first edge; and an upper part including a second edge and positioned on an opposite side to the lower part. The first edge and the second edge include a portion in which a frame line is not provided.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present invention relates to a mattress. [Background technology]

[0002] Mattresses are difficult to disassemble, and when they are discarded, they are often disposed of in landfills. However, in recent years, there has been a lack of landfill space in Japan, and the country is struggling to find a way to dispose of the waste. Therefore, there has been a demand for mattresses that are easy to disassemble and suitable for recycling.

[0003] For example, Patent Document 1 discloses a disassembly processing device used to separate the exterior body and spring unit of a mattress, and Patent Document 2 discloses a mattress structure designed to be easily disassembled. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 3459221 [Patent Document 2] Japanese Patent Application Publication No. 9-191976 Summary of the Invention [Problem to be solved by the invention]

[0005] Even considering the above-mentioned Patent Documents 1 and 2, there is still room for improvement in the technology for dismantling a mattress. Therefore, one of the objects of the present invention is to provide a mattress that can improve the work efficiency during dismantling. [Means for solving the problem]

[0006] A mattress according to one aspect of the present invention includes a spring unit having a plurality of coils and a wall member surrounding the spring unit. The spring unit has a lower portion including a first edge and an upper portion including a second edge and positioned opposite the lower portion, and the first edge and the second edge have portions without border lines.

[0007] The spring unit may have frame lines provided on at least a portion of the first edge and the second edge. The spring unit may be formed in a substantially rectangular parallelepiped shape that is elongated in the longitudinal direction, the first edge may have a pair of first short edges aligned in the longitudinal direction and a pair of first long edges aligned in a width direction perpendicular to the longitudinal direction, and the second edge may have a pair of second short edges aligned in the longitudinal direction and a pair of second long edges aligned in the width direction. The frame lines may be provided on each of the pair of first short edges and the pair of second short edges, and portions without the frame lines may be located on each of the pair of first long edges and the pair of second long edges.

[0008] The mattress may further include a first sheet material provided between the spring unit and the wall member and surrounding the side of the spring unit, and a second sheet material provided between the portion where the frame line is not provided and the first sheet material.

[0009] The mattress may further include a string-like member located between the spring unit and the outer peripheral surface of the wall member and extending along the outer periphery of the spring unit, the string-like member having an end portion protruding from the outer peripheral surface. The wall member may be made of foam. [Effects of the Invention]

[0010] According to the present invention, a mattress can be provided that can improve work efficiency when dismantling it. [Brief explanation of the drawings]

[0011] [Figure 1]FIG. 1 is a schematic perspective view of a mattress according to one embodiment. [Figure 2] FIG. 2 is an enlarged schematic perspective view showing the vicinity of the tab shown in FIG. [Figure 3] FIG. 3 is a perspective view schematically showing a scene in the mattress dismantling process. [Figure 4] FIG. 4 is a schematic perspective view of an inner body provided in the mattress. [Figure 5] FIG. 5 is a schematic cross-sectional view of the inner body taken along line VV shown in FIG. [Figure 6] FIG. 6 is a schematic cross-sectional view of the inner body taken along the line VI-VI shown in FIG. [Figure 7] FIG. 7 is a schematic exploded perspective view showing the spring unit, the first sheet material, and the second sheet material. [Figure 8] FIG. 8 is a schematic plan view of the inner body of the mattress. [Figure 9] FIG. 9 is a schematic plan view of the inner body of the mattress. [Figure 10] FIG. 10 is a schematic cross-sectional view illustrating the steps involved in forming the wall member. [Figure 11] FIG. 11 is a diagram showing measurement points in a vertical load test. DETAILED DESCRIPTION OF THE INVENTION

[0012] An embodiment will be described with reference to the drawings. In the following description, the "upper surface" of each element constituting the mattress refers to the surface facing the person sitting on it when the mattress is in use, and the "lower surface" of each element refers to the surface facing the floor when the mattress is in use. Also, the "side peripheral surface," "outer peripheral surface," and "inner peripheral surface" of each element refer to the surfaces connecting the upper and lower surfaces.

[0013] Each figure shows the X-axis, Y-axis, and Z-axis, which are perpendicular to each other. The direction along the X-axis is defined as the first direction X, the direction along the Y-axis is defined as the second direction Y, and the direction along the Z-axis is defined as the third direction Z.

[0014] In this embodiment, the first direction X corresponds to the width direction of the mattress 1, and the second direction Y corresponds to the longitudinal direction of the mattress 1. Viewing the mattress 1 parallel to the third direction Z is called a plan view.

[0015] Fig. 1 is a schematic perspective view of a mattress 1 according to this embodiment. The mattress 1 has, for example, a generally rectangular parallelepiped shape that is elongated in the second direction Y. The shape of the mattress 1 in a plan view has short sides along the first direction X and long sides along the second direction Y. In this case, the four corners of the mattress 1 may be smoothly curved (R-shaped).

[0016] The mattress 1 comprises an exterior body 2, an edge tape 3, and a tab 4 (tension tape). The exterior body 2 has a first portion 21 that covers the bottom and side surfaces of an interior body 5 (see FIG. 3) placed inside the exterior body 2, and a second portion 22 that covers the top surface of the interior body 5. Both the first portion 21 and the second portion 22 are made of a fabric material. The first portion 21 and the second portion 22 may be quilted.

[0017] The edge tape 3 connects the first portion 21 and the second portion 22. This closes the exterior body 2 into a bag shape. The edge tape 3 has a generally rectangular shape in plan view, with short sides aligned with the first direction X and long sides aligned with the second direction Y. The tab 4 is provided approximately in the center of the short side of the edge tape 3.

[0018] 2 is a schematic perspective view showing an enlarged view of the vicinity of the tab 4. The edge tape 3 is sewn to the peripheral edge of the first portion 21 and the peripheral edge of the second portion 22 by a pair of parallel stitching lines L.

[0019] The edge tape 3 has a first end 31 and a second end 32. The first end 31 is a portion that includes the end where sewing starts when sewing the edge tape 3 to the first portion 21 and the second portion 22, and its vicinity. The second end 32 is a portion that includes the end where sewing ends when sewing the edge tape 3 to the first portion 21 and the second portion 22, and its vicinity.

[0020] The second end 32 overlaps the outside of the first end 31. In other words, the first end 31 is located between the exterior body 2 and the second end 32. This forms a region R where the first end 31 and the second end 32 overlap.

[0021] Tab 4 is, for example, loop-shaped, and a portion thereof overlaps region R. Tab 4 also overlaps with a portion of second end 32 excluding region R (the portion to the right of region R in the drawing), but does not overlap with a portion of first end 31 excluding region R (the portion to the left of region R in the drawing).

[0022] 2, the tab 4 overlaps only one of the pair of suture lines L, but not the other. The tab 4 is disposed below the second end 32 (on the first portion 21 side), and is preferably located between the first end 31 and the second end 32 in the region R.

[0023] The edge tape 3 is sewn to the exterior body 2 from the sewing start end along the sewing direction DL. When this sewing operation reaches the second end 32, the tab 4 is sewn to the exterior body 2 together with the second end 32.

[0024] The edge tape 3 and tab 4 configured as described above contribute to facilitating the work of peeling off the exterior body 2 when dismantling the mattress 1. This effect will be explained using Figs.

[0025] 3 is a perspective view that schematically shows one scene in the process of dismantling the mattress 1. In the process of dismantling the mattress 1, as shown in the figure, the tab 4 is pulled and torn off from the edge tape 3. At this time, the bobbin thread that sews the second end 32 of the edge tape 3 to the exterior body 2 breaks. This makes it easier to peel the second end 32 from the exterior body 2.

[0026] 2 and 3 (the opposite direction to the sewing direction DL), the edge tape 3 is pulled and peeled off from the exterior body 2. When peeling is completed up to the first end 31, the first portion 21 and the second portion 22 of the exterior body 2 are completely separated. This makes it possible to remove the interior body 5 arranged inside the exterior body 2.

[0027] Next, the structure of the inner body 5 will be described with reference to FIGS.

[0028] FIG. 4 is a schematic perspective view of the inner body 5 included in the mattress 1. FIG. 5 is a schematic cross-sectional view of the inner body 5 taken along line VV in FIG. 4. FIG. 6 is a schematic cross-sectional view of the inner body 5 taken along line VI-VI in FIG. 4. FIG. 7 is a schematic exploded perspective view showing the spring unit 6, the first sheet material 81, and the second sheet materials 82A and 82B. FIGS. 8 and 9 are schematic plan views of the inner body 5 included in the mattress 1. In FIG. 5, the inner body 5 is viewed in the first direction X, and in FIG. 6, the inner body 5 is viewed in the second direction Y. In FIGS. 8 and 9, the protective materials 71A and 71B and the cushioning materials 72A and 72B are not shown. In FIG. 8, the inner body 5 is viewed in the third direction Z.

[0029] As shown in Fig. 4, the inner body 5 has an upper surface FA and a lower surface FB. The inner body 5 has, for example, a substantially rectangular parallelepiped shape that is elongated in the second direction Y. The inner body 5 has four corners C1, C2, C3, and C4. The corners C1, C2, C3, and C4 may have a smoothly curved (R-shaped) surface shape.

[0030] As shown in FIGS. 4 to 9, the inner body 5 includes a spring unit 6, protective materials 71A and 71B, cushion materials 72A and 72B, a first sheet material 81, second sheet materials 82A and 82B, and a wall member 9.

[0031] 5 and 6, protective material 71A is disposed on the upper surface side of spring unit 6, and protective material 71B is disposed on the lower surface side of spring unit 6. Cushion material 72A is disposed on the upper surface side of protective material 71A, and cushion material 72B is disposed on the lower surface side of protective material 71B. Protective materials 71A and 71B are formed of, for example, felt, sisal, or compressed cotton. Cushion materials 72A and 72B are formed of, for example, a foam such as urethane foam.

[0032] 7, the spring unit 6 is formed in a generally rectangular parallelepiped shape that is elongated in the second direction Y. The spring unit 6 has a lower portion 61 and an upper portion 62 located on the opposite side of the lower portion 61. The lower portion 61 includes a first edge 610 located on the outer periphery. The upper portion 62 includes a second edge 620 located on the outer periphery.

[0033] 8, the first edge 610 has a pair of first short edges 611, 612 aligned in the second direction Y and a pair of first long edges 613, 614 aligned in the first direction X. As shown in Fig. 9, the second edge 620 has a pair of second short edges 621, 622 aligned in the second direction Y and a pair of second long edges 623, 624 aligned in the first direction X.

[0034] 8 and 9, the spring unit 6 has a plurality of spring bodies 64. The plurality of spring bodies 64 are aligned in the second direction Y. The spring body 64 has a plurality of coils 641 formed by a single wire such as a steel wire, with their axes aligned substantially parallel to one another.

[0035] The multiple spring bodies 64 are connected by multiple helical wires 65. The multiple helical wires 65 extend in the second direction Y and are aligned in the first direction X. The helical wires 65 are wound around the upper and lower ends of the coils 641 of adjacent spring bodies 64, respectively. This connects the adjacent spring bodies 64.

[0036] The configuration of the spring unit 6 is not limited to the above example. The spring unit 6 may be configured, for example, with a plurality of spring bodies 64 aligned in the first direction X. In this case, adjacent spring bodies 64 are connected by a plurality of helical wires 65 extending in the first direction X and aligned in the second direction Y.

[0037] The spring unit 6 further has frame lines 66, 67, 68, and 69. The frame lines 66, 67, 68, and 69 have, for example, a substantially U-shape. The frame lines 66, 67, 68, and 69 are provided on at least a portion of the first edge 610 and the second edge 620. In the example shown in FIGS. 7 to 9, the frame lines 66 and 67 are provided on the pair of first short edges 611 and 612, and the frame lines 68 and 69 are provided on the pair of second short edges 621 and 622. In other words, the frame lines 66, 67, 68, and 69 are provided on the short sides of the upper and lower surfaces of the mattress 1, respectively.

[0038] Furthermore, frame lines 66 and 67 are also provided on parts of the first long edges 613 and 614, and frame lines 68 and 69 are also provided on parts of the second long edges 623 and 624. In other words, frame lines 66 and 67 are also provided on corners of the first edge 610, and frame lines 68 and 69 are also provided on corners of the second edge 620. Note that frame lines 66 and 67 do not necessarily have to be provided on the first long edges 613 and 614, and frame lines 68 and 69 do not necessarily have to be provided on the second long edges 623 and 624.

[0039] Ends 66a, 67a, 68a, 69a of the frame lines 66, 67, 68, 69 are bent toward the inside of the spring unit 6. In other words, the tips of the ends 66a, 67a, 68a, 69a of the frame lines 66, 67, 68, 69 protrude into the spring unit 6.

[0040] In terms of the first edge 610 and the second edge 620, the first edge 610 has a portion where the borders 66 and 67 are not provided, and the second edge 620 has a portion where the borders 68 and 69 are not provided.

[0041] The portions of the pair of first long edges 613, 614 where frame lines 66, 67 are not provided are referred to as portion NP1, and the portions of the pair of second long edges 623, 624 where frame lines 68, 69 are not provided are referred to as portion NP2. The portion NP1 is located on each of the pair of first long edges 613, 614, and the portion NP2 is located on each of the pair of second long edges 623, 624.

[0042] Portion NP1 is located in the second direction Y between end 66a of frame line 66 and end 67a of frame line 67, and portion NP2 is located in the second direction Y between end 68a of frame line 68 and end 69a of frame line 69.

[0043] The length in the second direction Y of portion NP1 is greater than the length in the second direction Y of portions of the first long edges 613, 614 other than portion NP1. The length in the second direction Y of portion NP2 is greater than the length in the second direction Y of portions of the second long edges 623, 624 other than portion NP2. The length in the second direction Y of portion NP1 is, for example, equal to the length in the second direction Y of portion NP2. The length in the second direction Y of portion NP1 may be different from the length in the second direction Y of portion NP1.

[0044] The frame lines 66, 67, 68, and 69 are formed of a hard material such as steel, hard synthetic resin, etc. The thickness of the wire material forming the frame lines 66, 67, 68, and 69 is greater than the thickness of the wire material forming the spring body 64 and the thickness of the wire material forming the helical wire 65, for example.

[0045] The wires forming the frame lines 66, 67, 68, and 69 have a diameter of, for example, 3 mm or more. In one example, the diameter is 3.5 mm. The frame lines 66, 67, 68, and 69 are each connected to the spring body 64 by a plurality of clips (not shown).

[0046] The wall member 9 surrounds the spring unit 6, the protection materials 71A and 71B, and the cushion materials 72A and 72B with the first sheet material 81 and the second sheet materials 82A and 82B sandwiched therebetween. The wall member 9 has, for example, a frame shape.

[0047] More specifically, the long side portions and short side portions of the wall member 9 are integrally formed. The length of the wall member 9 in the third direction Z is greater than the length of the spring unit 6 in the third direction Z, for example.

[0048] The wall member 9 is formed of a foam such as cold foam. The material for forming the foam is, for example, urethane. The wall member 9 is a relatively hard foam. The foam for forming the wall member 9 is harder than, for example, the first sheet material 81 and the second sheet materials 82A and 82B. Note that the wall member 9 does not have to be a foam, and may be formed of other resin materials or the like.

[0049] Wall member 9 has an inner circumferential surface 90 on the spring unit 6 side and an outer circumferential surface 91 located on the opposite side to inner circumferential surface 90. In such a configuration of inner body 5, the upper surfaces of cushion material 72A and wall member 9 correspond to upper surface FA of inner body 5, and the lower surfaces of cushion material 72B and wall member 9 correspond to lower surface FB of inner body 5.

[0050] The wall member 9 may have, for example, a slit 92 (see FIG. 4). The slit 92 is formed from the outer peripheral surface 91 toward the spring unit 6. In the example shown in FIG. 5, the slit 92 extends from the outer peripheral surface 91 to the inner peripheral surface 90. However, the slit 92 may also be formed in a range from the outer peripheral surface 91 to just before the inner peripheral surface 90.

[0051] The position of the slits 92 in the third direction Z is equivalent to the position in the third direction Z of the boundary between the spring unit 6 and the protective material 71A in the example shown in Fig. 5. The slits 92 are provided at the corners C1, C2, C3, and C4 in the example shown in Fig. 4. Between adjacent slits 92, the wall member 9 has a portion located above the slits 92 and a portion located below the slits 92 that are connected to each other.

[0052] The slits 92 may be provided at any one, two, or three of the corners C1, C2, C3, and C4. The slits 92 may also be provided at positions other than the corners C1, C2, C3, and C4.

[0053] The first sheet material 81 is provided between the spring unit 6 and the wall member 9. The first sheet material 81 surrounds the side of the spring unit 6, the protective materials 71A and 71B, and the side peripheral surfaces of the cushion materials 72A and 72B. The outer peripheral surface of the first sheet material 81 contacts, for example, the inner peripheral surface 90.

[0054] The second sheet materials 82A and 82B extend in the second direction Y and are arranged side by side in the first direction X. The second sheet materials 82A and 82B have a generally U-shape. The second sheet material 82A has a long side 84A extending along the second direction Y and short sides 85A and 86A extending along the first direction X. The second sheet material 82B has a long side 84B extending along the second direction Y and short sides 85B and 86B extending along the first direction X.

[0055] The long side portion 84B, the spring unit 6, and the long side portion 84A are arranged in this order in the first direction X. The long side portions 84A and 84B each have a portion located between the portions NP1 and NP2 and the first sheet material 81 in the first direction X.

[0056] The short side portion 86A, the spring unit 6, and the short side portion 85A are arranged in this order in the second direction Y, and the short side portion 86B, the spring unit 6, and the short side portion 85B are arranged in this order in the second direction Y.

[0057] In other words, the short side portions 85A, 85B are located between the frame lines 66, 68 and the first sheet material 81 in the second direction Y, and the short side portions 86A, 86B are located between the frame lines 67, 69 and the first sheet material 81 in the second direction Y.

[0058] The short side portion 85A is spaced apart from the short side portion 85B in the first direction X, and the short side portion 86A is spaced apart from the short side portion 86B in the first direction X. In other words, the spring unit 6 has a portion NP3 in the second direction Y that does not overlap with the second sheet materials 82A and 82B.

[0059] The first sheet material 81 and the second sheet materials 82A, 82B are formed of a foam such as urethane foam. The thickness of the first sheet material 81 is, for example, smaller than the thickness of the second sheet materials 82A, 82B. The thickness of the first sheet material 81 may be larger than the thickness of the second sheet materials 82A, 82B, or may be equal to the thickness of the second sheet materials 82A, 82B.

[0060] The mattress 1 may further include string members S10 as shown in Fig. 4. In one example, the string members S10 are made of silk, but are not limited to this example. The cross-sectional shape of the string members S10 is circular in one example, but may be rectangular or another shape.

[0061] The string-shaped member S10 is provided along the outer periphery of the spring unit 6. The string-shaped member S10 may be provided along the entire outer periphery of the spring unit 6, or may be provided along only a part of the outer periphery of the spring unit 6, for example.

[0062] The string-like member S10 is located between the spring unit 6 and the outer peripheral surface 91 of the wall member 9. The string-like member S10 may be provided inside the wall member 9 as shown in FIGS. 5 and 6. In this case, the string-like member S10 is located, for example, on the inner peripheral surface 90 side inside the wall member 9. In another example, the string-like member S10 may be provided between the wall member 9 and the first sheet material 81.

[0063] The string-shaped member S10 has an end portion S10a that protrudes from the outer circumferential surface 91. In the example shown in Fig. 4, the end portion S10a protrudes from a slit 92 in the wall member 9. The end portion S10a may protrude from a portion of the outer circumferential surface 91 other than the slit 92.

[0064] The end S10a only needs to be long enough for the user to hold it. The end S10a functions as a grip when dismantling the mattress 1. The end (not shown) of the string-like member S10 opposite the end S10a may be connected to the spring unit 6 or to a member other than the spring unit 6.

[0065] A single string-shaped member S10 may be provided along the outer periphery of the spring unit 6, or multiple string-shaped members S10 may be provided along the outer periphery of the spring unit 6. When multiple string-shaped members S10 are provided, multiple end portions S10a may protrude from the outer periphery 91.

[0066] Here, the steps relating to the formation of the wall members 9 in the method for manufacturing the mattress 1 will be described. 10 is a schematic cross-sectional view showing a process for forming the wall member 9. When forming the wall member 9, a laminate M is placed on a workbench 100. The laminate M is formed by stacking cushion material 72B, protective material 71B, spring unit 6, protective material 71A, and cushion material 72A in this order. Furthermore, a first sheet material 81 and second sheet materials 82A and 82B are provided on the outer periphery of the laminate M.

[0067] The workbench 100 is provided with a plurality of frame bodies 110. The frame bodies 110 are connected to the ends of the workbench 100 by, for example, hinges, and are rotatable from a reclined position as shown by the dashed lines to an upright position as shown by the solid lines.

[0068] The frame 110 is made of, for example, a metal material, a resin material, or wood. The frame 110 is provided on each of the four sides of the laminate M. When the frame 110 is erected, the side periphery of the laminate M is surrounded by the frame 110.

[0069] At this time, a gap G is formed between the frame body 110 and the laminated body M. With the frame body 110 in an upright state, a liquid agent Q that will become the base of the wall member 9 is injected into the gap G. The liquid agent Q injected into the gap G foams, thereby forming the wall member 9.

[0070] As a result, the long side portions and short side portions of the wall member 9 are integrally formed. The work table 100 and the laminate M may be temperature-controlled at a predetermined temperature, for example, before, during, and after the injection of the liquid agent Q.

[0071] Although not shown, a plurality of plates for forming the slits 92 may be further arranged on the workbench 100. The plurality of plates may be made of, for example, plastic. After the wall member 9 is formed, each plate is removed, and slits 92 corresponding to the shape of the plate are formed in the wall member 9. Although not shown, the string-like member S10 described with reference to FIG. 4 may be arranged in the gap G. In this way, the string-like member S10 is provided inside the wall member 9.

[0072] After the wall members 9 are formed, the frame 110 is removed. This forms the inner body 5, which is an integrated unit of the wall members 9 and the spring unit 6. Thereafter, the inner body 5 is connected to the first portion 21 and the second portion 22 of the outer body 2 with the edge tape 3, and the mattress 1 is completed.

[0073] When dismantling the mattress 1, as explained with reference to Figure 3, the edge tape 3 is peeled off from the exterior body 2, the first portion 21 and the second portion 22 are separated, and the interior body 5 is removed. Next, the protective material 71A and the cushioning material 72A are separated from the spring unit 6 and the wall member 9. When the protective material 71A and the cushioning material 72A are separated, the upper surface side of the spring unit 6 is exposed. In this state, the spring unit 6 can be removed.

[0074] In the mattress 1 configured as described above, the first edge 610 of the spring unit 6 has the portion NP1, and the second edge 620 has the portion NP2. Therefore, when disassembling the removed spring unit 6, there is no need to cut the frame lines in the portions NP1 and NP2.

[0075] If a frame line is provided around the entire periphery of the spring unit, the frame line must be cut. Because the wire that forms the frame line is thick, it is difficult to cut the frame line with commercially available tools. As a result, the work of dismantling the spring unit took a long time.

[0076] The wire material forming the spring body 64 and the helical wire 65 of the spring unit 6 is thinner than the wire material forming the frame wire, so the user can easily cut the wire material forming the spring body 64 and the helical wire 65.

[0077] With the spring unit 6, it is possible to disassemble the spring unit 6 into multiple parts by cutting the wire material that forms the spring bodies 64 and the helical wire 65, without cutting the frame line. In this way, with this embodiment, it is possible to improve the work efficiency when dismantling the mattress 1.

[0078] For example, it has been difficult to load a large spring unit into a private car or the like when disposing of it. With the mattress 1 according to this embodiment, the spring unit 6 can be disassembled to a desired size without cutting the frame lines. In other words, the user can disassemble the spring unit 6 to a size that can be loaded into a private car or the like, and then dispose of it.

[0079] In this embodiment, the pair of first long edges 613, 614 have a portion NP1, and the pair of second long edges 623, 624 have a portion NP2. Therefore, when disassembling, the spring unit 6 can be cut along the first direction X. For example, the user can disassemble the spring unit 6 into multiple parts by cutting the multiple helical wires 65 aligned in the first direction X.

[0080] In this way, with the mattress 1 according to this embodiment, the frame lines 66, 67, 68, 69 are less likely to get in the way when the spring unit 6 is dismantled, and the work of dismantling the mattress 1 can be carried out efficiently.

[0081] In this embodiment, the mattress 1 includes a wall member 9. The wall member 9 is formed of a relatively hard material. Here, the results of a vertical load test specified in JIS S 1102 "Ordinary bed for residential use" are shown.

[0082] Fig. 11 is a diagram showing measurement points in a vertical load test. In the example shown in Fig. 11, the upper side in the figure corresponds to the head side, and the lower side in the figure corresponds to the head side. As shown in Fig. 11, the measurement points in the vertical load test are a first measurement point A1, a second measurement point A2, and a third measurement point A3. The second measurement point A2 corresponds to approximately the center of the mattress.

[0083] These measurement points A1, A2, and A3 are located approximately in the center of the mattress in the second direction Y. In the case of the mattress 1 according to this embodiment, these measurement points A1, A2, and A3 overlap with the portions NP1 and NP2 in the first direction X. In other words, the first measurement point A1 and the third measurement point A3 are included in the portions NP1 and NP2 of the spring unit 6 and their neighboring areas.

[0084] In the vertical load test, a force is applied by a pressure plate with a diameter of 20 cm. In this case, the pressure plate applies a force to the wall member and the spring unit at the first measurement point A1 and the third measurement point A3.

[0085] Based on the above standards, the deflection increase D1 at the first measurement point A1, the second measurement point A2, and the third measurement point A3 is calculated using the following formula: [Formula] D1=δ350-δ150 In the formula, δ150 is the deflection (mm) when a load of 150N is applied, and δ350 is the deflection (mm) when a load of 350N is applied.

[0086] The test results for mattress 1 were that the deflection increase D1 at the first measurement point A1 was 27 mm, the deflection increase D1 at the second measurement point A2 was 31 mm, and the deflection increase D1 at the third measurement point A3 was 30 mm.

[0087] It was confirmed that there was almost no difference in the deflection increase D1 at measurement points A1, A2, and A3 in the mattress 1 according to this embodiment. Because the mattress 1 includes a wall member 9 that surrounds the spring unit 6, the first measurement point A1 and the third measurement point A3 have the same degree of hardness as the second measurement point A2.

[0088] The mattress according to the comparative example has a frame line around the entire periphery of the spring unit, in other words, the spring unit of the mattress according to the comparative example does not have the portions NP1 and NP2.

[0089] The test results for the mattress of the comparative example were that the deflection increase D1 at the first measurement point A1 was 24 mm, the deflection increase D1 at the second measurement point A2 was 28 mm, and the deflection increase D1 at the third measurement point A3 was 26 mm.

[0090] It was confirmed that the mattress 1 had the same increased deflection D1 at each of the measurement points A1, A2, and A3 as the mattress of the comparative example. In other words, the mattress 1 had the same degree of hardness at each of the measurement points A1, A2, and A3 as the mattress of the comparative example.

[0091] That is, it was confirmed that the hardness of the mattress 1 is maintained in the portions NP1 and NP2 of the spring unit 6 and their vicinity. More specifically, the mattress 1 is capable of maintaining the shape of the spring unit 6 in the portions NP1 and NP2 of the spring unit 6 and their vicinity.

[0092] With mattress 1, it is possible to prevent unnatural sinking in portions NP1, NP2 and their vicinity. This allows mattress 1 to provide sleeping comfort equivalent to that of the mattress according to the comparative example. Therefore, with mattress 1 according to this embodiment, it is possible to improve work efficiency during disassembly while also ensuring sleeping comfort.

[0093] Furthermore, in the case of mattress 1, the wall members 9 make it possible to use the outer periphery of mattress 1. In other words, it is possible to ensure a large area (effective area) of the upper surface of mattress 1 that can be used by the user.

[0094] The spring unit 6 has frame lines 66, 67, 68, 69 provided on the pair of first short edges 611, 612 and the pair of second short edges 621, 622. This makes it possible to prevent the spring body 64 of the spring unit 6 from becoming entangled with the pair of first short edges 611, 612 and the pair of second short edges 621, 622 when the spring unit 6 sinks.

[0095] The wall member 9 has a slit 92. As a result, when dismantling the mattress 1, by lifting the end of the wall member 9 on the upper surface FA side near the slit 92, the wall member 9 can be easily torn starting from the slit 92. This makes it possible to separate the wall member 9 into an upper surface side and a lower surface side. As a result, the work of dismantling the mattress 1 can be made more efficient.

[0096] 4 is provided, by pulling the end S10a of the string-like member S10, the string-like member S10 cuts the wall member 9, and the wall member 9 can be separated into an upper surface side and a lower surface side. In particular, when the string-like member S10 is provided over the entire outer periphery of the spring unit 6, the entire wall member 9 can be separated into an upper surface side and a lower surface side.

[0097] The mattress 1 includes a first sheet material 81 and second sheet materials 82A and 82B. The first sheet material 81 and the second sheet materials 82A and 82B prevent the liquid agent Q from flowing into the spring unit 6 during the process of forming the wall member 9.

[0098] Gaps are particularly likely to occur near the portions NP1 and NP2 of the laminate M. In this embodiment, second sheet materials 82A and 82B are provided between the portions NP1 and NP2 and the first sheet material 81. This makes it difficult for such gaps to form, and makes it possible to reliably prevent the liquid agent Q from flowing into the spring unit 6.

[0099] The scope of the present invention is not limited to the configurations disclosed in the above-described embodiments. The present invention can be implemented by modifying the configurations disclosed in the present embodiments in various ways.

[0100] It should be noted that a mattress can also be constructed by combining the outer body 2 in the above embodiment with an inner body having a different structure from that in the above embodiment. Also, a mattress can also be constructed by combining the inner body 5 in the above embodiment with an outer body having a different structure from that in the above embodiment. The spring unit 6 may be constructed, for example, by blocks divided into multiple (e.g., two or three) parts in the second direction Y.

[0101] In this embodiment, portions NP1 and NP2 are located on a pair of first long edges 613 and 614 and a pair of second long edges 623 and 624, but frame lines may be provided so that portions NP1 and NP2 are located on a pair of first short edges 611 and 612 and a pair of second short edges 621 and 622. [Explanation of symbols]

[0102] 1...Mattress, 2...Exterior body, 3...Edge tape, 4...Tab, 5...Interior body, 6...Spring unit, 9...Wall member, 61...Lower part, 62...Upper part, 66, 67, 68, 69...Frame line, 71A, 71B...protective material, 72A, 72B...cushioning material, 81...first sheet material, 82A, 82B...second sheet material, 610...first edge, 611, 612...first short edge, 613, 614...first long edge, 620...second edge, 621, 622...second short edge, 623, 624...second long edge, 641...coil, NP1, NP2...portion, S10...string-like member, S10a...end portion.

Claims

1. A spring unit formed in a substantially rectangular parallelepiped shape that is long in the longitudinal direction and has a plurality of coils; a wall member surrounding the spring unit; a first sheet material provided between the spring unit and the wall member and surrounding a side portion of the spring unit; a second sheet material, The spring unit is a lower portion including a first edge including a pair of first short edges aligned in the longitudinal direction and a pair of first long edges aligned in a width direction perpendicular to the longitudinal direction; an upper portion located opposite the lower portion and including a second edge including a pair of second short edges aligned in the longitudinal direction and a pair of second long edges aligned in the width direction; frame lines provided on the pair of first short edges and the pair of second short edges; and the pair of first long edges and the pair of second long edges each have a portion where the frame line is not provided, The second sheet material is provided between the portion where the frame line is not provided and the first sheet material. mattress.

2. a string-shaped member positioned between the spring unit and the outer circumferential surface of the wall member and provided along the outer periphery of the spring unit; The string-like member has an end portion protruding from the outer circumferential surface. The mattress of claim 1.

3. The wall member is formed of a foam.

3. A mattress according to claim 1 or 2.

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