Compression mattress and method for manufacturing a compression mattress

Abstract

To provide a compressed mattress capable of being excellently restored to a shape before compression when a storage bag is opened, and a method for manufacturing the same.SOLUTION: In a compressed mattress (1) in which a mattress main body (3) is compressed and stored in a storage bag (4) in a sealed manner in a state of being stored inside a cover (2) and wound in a roll shape, the mattress main body (3) is formed of a filament three-dimensional bonded body in which filaments are knitted in a front-back direction which is a height direction of a lying person, a right-left direction, and an up-down direction, and the front-back direction and the right-left direction orthogonal to a compression direction are harder than the up-down direction which is the compression direction. An upper surface (6) and / or a lower surface (7) of the mattress main body (3) are made harder than an intermediate part (8) between the upper surface (6) and the lower surface (7). The upper surface (6) or the lower surface (7) of the mattress main body (3) on the outer side when wound in a roll shape is harder than the lower surface (7) or the upper surface (6) of the mattress min body (3) on the inner side.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a compressed mattress that is compression-sealed in a storage bag in a state where a mattress body is housed inside a cover and wound into a roll, and a method for manufacturing the compressed mattress. Background Art

[0002] A mattress maintains elasticity and heat insulating properties by containing air inside, such as cotton or urethane. Therefore, a mattress can provide a comfortable feeling to a user when used in a state where air is taken into the interior thereof.

[0003] On the other hand, a mattress has a large volume when air is taken into the interior thereof. For this reason, it is difficult to easily transport the mattress.

[0004] Accordingly, conventionally, it has been proposed to compress and store a mattress in a storage bag (see, for example, Patent Document 1). Prior Art Documents Patent Documents

[0005] Patent Document 1 Japanese Unexamined Patent Publication No. 2009-29501 Summary of the Invention Problems to be Solved by the Invention

[0006] In recent years, as a cushioning material inside a mattress, a mattress body formed of a three-dimensional filament bonded body extending in the front-rear direction corresponding to the height direction of a person lying down, the left-right direction, and the vertical direction has been used. In this conventional mattress, the mattress body is formed by knitting filaments made of a plurality of molten thermoplastic resin fibers into a three-dimensional net shape, such that the filament density is constant in the vertical direction, the front-rear direction, and the left-right direction.

[0007] However, when the mattress body, which consists of the three-dimensional filament assembly described above, is stored inside the cover, compressed and sealed in a storage bag, and then rolled up, a problem occurs where the mattress body does not return to its compressed shape even after the storage bag is opened. [Means for solving the problem]

[0008] Therefore, in the present invention according to claim 1, a compressed mattress is stored in a sealed storage bag with the mattress body inside the cover and then rolled up, wherein the mattress body is made of a three-dimensional filament assembly in which filaments are arranged in the front-to-back direction, left-to-right direction, and up-and-down direction, which are the direction of the height of a person lying down, and the front-to-back and left-to-right directions, which are perpendicular to the compression direction, are harder than the up-and-down direction, which is the compression direction. Furthermore, when rolled up, the upper or lower surface of the mattress body that is on the outside is made harder than the lower or upper surface of the mattress body that is on the inside. I decided to do it.

[0009] Furthermore, in the present invention according to claim 2, the upper surface and / or lower surface of the mattress body is made harder than the intermediate portion between the upper surface and the lower surface, as in the present invention according to claim 1.

[0011] Also, Claim 3 In the present invention relating to the present invention, a method for manufacturing a compressed mattress in which the mattress body is stored inside a cover, compressed and sealed in a storage bag, and wound into a roll, is made of a three-dimensional filament assembly in which filaments are arranged in the front-to-back direction, left-to-right direction, and up-and-down direction, which correspond to the height of a person lying down, and the front-to-back and left-to-right directions, which are perpendicular to the compression direction, are made harder than the up-and-down direction, which is the compression direction. When rolled up, the upper or lower surface of the mattress body that is on the outside is made harder than the lower or upper surface of the mattress body that is on the inside. We decided to use a mattress body, compress the mattress body vertically, and then roll it up into a roll shape. [Effects of the Invention]

[0012] Furthermore, the present invention provides the following effects.

[0013] In other words, the present invention provides a compressed mattress in which the mattress body is stored inside a cover, compressed and sealed in a storage bag, and wound into a roll, and a method for manufacturing the same. The mattress body is made of a three-dimensional filament assembly in which filaments are arranged in the front-to-back direction, left-to-right direction, and up-and-down direction, which correspond to the height of a person lying down. The front-to-back and left-to-right directions, which are perpendicular to the compression direction, are made harder than the up-and-down direction, which is the compression direction. Therefore, when the storage bag is opened, the mattress body can be well restored to its shape before compression.

[0014] In particular, if the upper surface and / or lower surface of the mattress body is made harder than the intermediate part between the upper and lower surfaces, opening the storage bag will allow the mattress body to be restored to its pre-compression shape even more effectively.

[0015] Furthermore, if the upper or lower surface of the mattress body, which is on the outside when rolled up, is made harder than the lower or upper surface of the mattress body, it is possible to prevent the mattress body from developing a bend when it is restored to its pre-compression shape by opening the storage bag. [Brief explanation of the drawing]

[0016] [Figure 1] An explanatory diagram showing a compression mattress according to the present invention. [Figure 2] Side cross-sectional view (a) and enlarged view (b) of the mattress body. [Figure 3] An explanatory diagram showing the manufacturing method of a compressed mattress. [Modes for carrying out the invention]

[0017] The specific configuration of the compression mattress and its manufacturing method according to the present invention will be described below with reference to the drawings.

[0018] As shown in Fig. 1, the compressed mattress 1 is obtained by compression-packing a mattress body 3 housed inside a cover 2 in a sealed state into a storage bag 4, and winding the same into a roll shape.

[0019] When the storage bag 4 is opened for this compressed mattress 1, air enters the mattress body 3 inside the storage bag 4, and the mattress body 3 housed inside the cover 2 is restored to its shape before compression, thereby forming a rectangular plate-shaped mattress 5.

[0020] The cover 2 only needs to be capable of housing the rectangular plate-shaped mattress body 3, and is made of a flexible material (for example, cloth) whose shape changes along with compression of the mattress body 3. This cover 2 may be provided with an openable / closable fastener at an opening for attaching / detaching the mattress body 3.

[0021] As shown in Fig. 2, the mattress body 3 is entirely formed integrally by a three-dimensional filament bonded body in which filaments are knitted in the front-back direction (the left-right direction in Fig. 2) corresponding to the height direction of a person lying down, as well as in the left-right direction and the up-down direction, and is formed into a rectangular plate shape extending in the front-back direction corresponding to the height direction of a person lying down, and the left-right direction and the up-down direction orthogonal to the front-back direction. Here, the three-dimensional filament bonded body is formed by dropping filaments formed of a plurality of thermoplastic resin fibers in a molten state from above, fusing the filaments to each other into a three-dimensional net shape, and then cooling the same. As the filaments, a thermoplastic resin material such as polyethylene or polypropylene is used.

[0022] In this mattress body 3, an intermediate portion 8, which is a layer thicker than the upper surface 6 and the lower surface 7 (having a greater length in the up-down direction), is formed between the upper surface 6 serving as a planar layer formed on the upper side and the lower surface 7 serving as a planar layer formed on the lower side.

[0023] The upper surface 6 and the lower surface 7 have the same lengths in the front-back direction and the left-right direction as the intermediate portion 8, and only the length (thickness) in the up-down direction is shorter and thinner than that of the intermediate portion 8.

[0024] Furthermore, the upper surface 6 and the lower surface 7 have a higher filament density than the intermediate section 8, so that they are harder in the vertical direction than the intermediate section 8. Alternatively, only the upper surface 6 or the lower surface 7 may have a higher filament density than the intermediate section 8, so that they are harder in the vertical direction than the intermediate section 8.

[0025] The upper surface 6 and the lower surface 7 may have the same filament density and therefore the same hardness. However, in this case, when winding the material into a roll to form the compressed mattress 1, the side located on the outside of the roll (lower surface 7) has a higher filament density than the side located on the inside of the roll (upper surface 6), so that it is harder in the vertical direction.

[0026] Thus, the mattress body 3 is formed so that the hard portions of the upper surface 6 and lower surface 7, which have a higher filament density and are harder than the intermediate portion 8, are extended in the front-to-back and left-to-right directions, creating a planar structure. As a result, the mattress body 3 is harder in the front-to-back and left-to-right directions, which are perpendicular to the compression direction, than in the up-to-down direction, which is the compression direction during the manufacturing of the compression mattress 1 described later.

[0027] Compression mattress 1 can be manufactured as described below.

[0028] First, as shown in Figure 3(a), the mattress body 3 is placed inside the cover 2 to form the mattress 5. The mattress 5 (cover 2 and mattress body 3) is in an inflated state with air inside, just as it would be during use.

[0029] Next, as shown in Figure 3(b), a nonwoven fabric 9, slightly larger than the bottom surface of the mattress 5, is placed directly beneath the mattress 5. Furthermore, a flexible sheet 10, such as transparent vinyl, slightly larger than the bottom surface of the mattress 5 and the nonwoven fabric 9, is placed directly beneath the nonwoven fabric 9. Additionally, a nonwoven fabric 11, slightly larger than the top surface of the mattress 5, is placed directly above the nonwoven fabric 11. Furthermore, a flexible sheet 12, such as transparent vinyl, slightly larger than the top surface of the mattress 5 and the nonwoven fabric 11, is placed directly above the nonwoven fabric 11.

[0030] Next, as shown in Figure 3(c), with the mattress 5 stretched in the front-to-back direction (left-to-right direction in Figure 3) corresponding to the height of the person lying on their side, the mattress 5 sandwiched between the upper and lower sheets 10, 12 and the nonwoven fabrics 9, 11 is compressed from above, compressing it in the vertical direction and forcibly expelling the air from inside the mattress 5 and between the mattress 5 and the upper and lower sheets 10, 12 and the nonwoven fabrics 9, 11 to the outside.

[0031] Next, as shown in Figure 3(d), the outer edges (periphery) of the upper and lower sheets 10 and 12 that protrude outward from the outer periphery of the mattress 5 and the upper and lower nonwoven fabrics 9 and 11 are sealed together by heat welding or the like. This forms a storage bag 4 consisting of the upper and lower sheets 10 and 12 with the mattress 5 and the upper and lower nonwoven fabrics 9 and 11 stored inside.

[0032] In the end, the mattress body 3 should be stored inside the cover 2 and then compressed and sealed in the storage bag 4. For example, the mattress 5 and the upper and lower nonwoven fabrics 9 and 11 may be stored in a flexible storage bag 4 with an opening before being compressed.

[0033] Next, as shown in Figure 3(e), the mattress 5, which is compressed and sealed in the storage bag 4, is rolled up. Here, the mattress 5 is rolled up from the end side along its length so that the top surface of the mattress 5 and the top surface 6 of the mattress body 3 are always inside the bottom surface of the mattress 5 and the bottom surface 7 of the mattress body 3 at the same position, resulting in a smaller rolling radius.

[0034] As described above, a compressed mattress 1 can be manufactured in which the mattress body 3 is stored inside the cover 2, compressed and sealed in the storage bag 4, and then rolled up, as shown in Figure 3(f).

[0035] The compressed mattress 1 can be immediately used after the storage bag 4 is torn open and air is allowed inside, restoring the mattress 5 (mattress body 3) to its inflated state.

[0036] As described above, the compressed mattress 1 consists of a mattress body 3 made of a three-dimensional filament assembly in which filaments are arranged in the front-to-back direction, left-to-right direction, and up-and-down direction, which correspond to the height of a person lying on their side. The front-to-back and left-to-right directions, which are perpendicular to the compression direction, are harder than the up-and-down direction, which is the compression direction.

[0037] Therefore, with the above-described configuration of the compressed mattress 1, the compressed mattress 1 can be transported in a compressed state, thus reducing the occupied area and lowering transportation costs. Moreover, by opening the storage bag 4, the mattress body 3 can be restored to its original shape before compression.

[0038] Furthermore, the compressed mattress 1 described above has a configuration in which the upper surface 6 and / or the lower surface 7 of the mattress body 3 is harder than the intermediate portion 8 between the upper surface 6 and the lower surface 7.

[0039] Therefore, with the compressed mattress 1 configured as described above, opening the storage bag 4 allows the mattress body 3 to be restored to its pre-compression shape even more effectively.

[0040] Furthermore, the compressed mattress 1 described above has a configuration in which the upper surface 6 or lower surface 7 of the mattress body 3, which is on the outside when rolled up, is harder than the lower surface 7 or upper surface 6 of the mattress body 3, which is on the inside.

[0041] Therefore, with the above-described configuration of the compressed mattress 1, when the storage bag 4 is opened and the mattress body 3 is restored to its pre-compression shape, it is possible to prevent the mattress body 3 from flattening out on its own and forming a bend in the mattress body 3. [Explanation of Symbols]

[0042] 1. Compressed mattress 2. Cover 3. Mattress itself 4. Storage bag 5 Mattress 6 Top surface 7 Bottom surface 8 Middle part 9,11 Nonwoven fabric 10,12 Sheet

Claims

1. In a compressed mattress in which the mattress body is stored inside the cover, compressed and sealed in a storage bag, and then rolled up, The mattress body is made of a three-dimensional filament assembly in which filaments are arranged in the front-to-back direction, left-to-right direction, and up-and-down direction, corresponding to the height of a person lying down. The front-to-back and left-to-right directions, which are perpendicular to the compression direction, are harder than the up-and-down direction, which is the compression direction. The upper or lower surface of the mattress body, which is on the outside when rolled up, is harder than the lower or upper surface of the mattress body, which is on the inside.

2. The compression mattress according to claim 1, characterized in that the upper surface and / or lower surface of the mattress body is harder than the intermediate portion between the upper surface and the lower surface.

3. In a method for manufacturing a compressed mattress in which the mattress body is stored inside a cover, compressed and sealed in a storage bag, and then rolled up, A method for manufacturing a compressed mattress, characterized by using a mattress body made of a three-dimensional filament assembly in which filaments are arranged in the front-to-back direction, left-to-right direction, and up-and-down direction, corresponding to the height of a person lying down, with the front-to-back and left-to-right directions being harder than the up-and-down direction which is the compression direction, and the upper or lower surface of the mattress body that becomes the outer surface when wound into a roll being harder than the lower or upper surface of the mattress body that becomes the inner surface, and compressing the mattress body in the up-and-down direction before winding it into a roll.

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