Cushion member and mat member

Abstract

Provided is a cushion member and a mat member that can improve the ability to roll over and / or the distribution of body pressure.　A cushion member 20, 120, 220, 320, 420, 520, 620 is formed of an elastic material, and comprises small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a which are separated by a plurality of slits Sa, Sb, Sc, Sd, Se1, Se2, Sf which are formed so as to intersect with other slits Sa, Sb, Sc, Sd, Se1, Se2, Sf.

Description

Cushion member and mat member

[0001] The present invention relates to a cushion member and a mat member.

[0002] As cushion and mat components, Patent Document 1 discloses a mattress formed by stacking multiple layers of multi-cell foam cushioning material, each layer having a progressively harder hardness from top to bottom. This mattress has multiple slits extending from the top to bottom, with at least one edge of each slit being close to the edge of an adjacent slit. These slits have an I-shaped or Y-shaped planar shape. This allows for a resilience similar to that experienced by the body when floating in water, regardless of the load or surface area, achieving both a soft sleeping comfort and a proper sleeping posture.

[0003] Furthermore, Patent Document 2 discloses a cushioning material formed by stacking multiple sheets of nonwoven fabric 1, 1... as a cushioning member and a matting member. In this cushioning material, at least one sheet of nonwoven fabric 1 has multiple radial slits 2, 2... formed therein. The radial slits 2 have four or more slits extending radially from any point. As a result, when the weight of the body is applied to the cushioning material, the radial slits 2, 2... each rupture, dispersing the weight downward and weakening the repulsive force of the cushioning material against the body. As a result, the adhesion between the cushioning material and the body can be reduced, and bedsores can be prevented.

[0004] Japanese Patent Laid-Open No. 09-121985 Japanese Patent Laid-Open No. 2001-234458

[0005] The mattress disclosed in the above-mentioned Patent Document 1 can achieve both a soft sleeping comfort and an appropriate sleeping posture, and the cushioning material disclosed in the above-mentioned Patent Document 2 can reduce the adhesion between the cushioning material and the body, but there is a demand for improving at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0006] The present invention has been made to solve the above-mentioned problems, and aims to provide a cushion member and a mat member that can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0007] In order to solve the above problems, the cushion member of the present invention is a cushion member formed of an elastic material and is characterized by having small elastic bodies separated by a plurality of slits formed so as to intersect with other slits.

[0008] According to the cushion member of the present invention, the small elastic bodies can support the body independently and can undergo compressive deformation according to the weight distribution of the body, thereby improving at least one of the cushion member's ability to turn over in sleep and its ability to distribute body pressure.

[0009] The cushion member according to the present invention is a cushion member formed of an elastic material and is characterized by comprising small elastic bodies partitioned by continuous cuts having a predetermined linear shape.

[0010] According to the cushion member of the present invention, the small elastic bodies can support the body independently and can undergo compressive deformation according to the weight distribution of the body, thereby improving at least one of the cushion member's ability to turn over in sleep and its ability to distribute body pressure.

[0011] In addition, in the cushion member according to the present invention, it is preferable that the small elastic bodies are connected to the adjacent members by connecting portions. In this way, since the small elastic bodies are connected to the adjacent members by connecting portions, it is possible to prevent the small elastic bodies from tipping over due to the load, and it is possible to achieve both compressive deformation according to the body weight distribution and prevention of tipping over. Therefore, it is possible to further improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0012] In the cushion member according to the present invention, the connecting portion is preferably formed between two adjacent intersections of the slits or at the intersections, which makes it possible to easily and reliably form the connecting portion at an appropriate position on the slits.

[0013] Furthermore, in the cushion member according to the present invention, it is preferable that the cushion member has the slit on the surface side that can be touched by a person, and the connecting portion is connected at the end of the back side of the cushion member in the thickness direction. In this way, since the connecting portion is provided on the back side of the cushion member in the thickness direction, the small elastic bodies can support the body more independently and can compressively deform in accordance with the body weight distribution more effectively. Therefore, the cushion member can further improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0014] Furthermore, in the cushion member according to the present invention, it is preferable that the small elastic bodies are partitioned by forming the linear shape of the slits so that the surface area of ​​the small elastic bodies varies depending on the location on the surface of the cushion member. This makes it possible to form small elastic bodies with surface areas that correspond to the body parts supported by the cushion member, allowing them to be compressed and deformed in accordance with the body (body weight distribution) being supported. Therefore, the cushion member can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0015] A mat member according to the present invention is characterized in that it is formed by arranging a plurality of cushion members according to the first or second aspect.

[0016] In the mattress member according to the present invention, the small elastic bodies can support the body independently and can undergo compressive deformation according to the weight distribution of the body, thereby improving at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0017] According to the present invention, it is possible to provide a cushion member and a mat member that can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0018] 4A is an external perspective view showing an embodiment of a cushion member 20 and a mat member 10 according to the present invention. FIG. 4B is an exploded perspective view showing an embodiment of a cushion member 20 and a mat member 10 according to the present invention. FIG. 4C is a front view showing the mat member 10 shown in FIGS. 1 and 2. FIG. 4D is a bottom view showing the mat member 10 shown in FIGS. 1 and 2. FIG. 4E is a left side view showing the mat member 10 shown in FIGS. 1 and 2. FIG. 4F is a right side view showing the mat member 10 shown in FIGS. 1 and 2. FIG. 4G is a plan view showing the cushion member 20 (first zone right mat 12b) shown in FIGS. 1 and 2. FIG. 4H is a left side view showing the cushion member 20 (first zone right mat 12b) shown in FIGS. 1 and 2. FIG. 4H is a rear view showing the cushion member 20 (first zone right mat 12b) shown in FIGS. 4A and 4B. FIG. 4G is a partially enlarged plan view showing the cushion member 20 (first zone right mat 12b) shown in FIG. 4A. FIG. 4H is a partially enlarged plan view showing a cushion member 120 (connecting portions arranged at intersections) according to Modification 1. FIG. 4I is an exploded perspective view showing a cushion member 220 and a mat member 210 according to Modification 2. 1 is a plan view showing a cushion member 220 according to Modification 2. FIG. 2 is a left side view showing a cushion member 220 according to Modification 2. FIG. 3 is a rear view showing a cushion member 220 according to Modification 2. FIG. 4 is a plan view showing a cushion member 320 according to a modified example of the slit shape (regular hexagon). FIG. 5 is a plan view showing a cushion member 420 according to a modified example of the slit shape (diamond). FIG. 6 is a plan view showing a cushion member 520 according to a modified example of the slit shape (hemp leaf pattern). FIG. 7 is a plan view showing a cushion member 620 according to a modified example of the slit shape (shippo pattern).

[0019] An embodiment of the cushion member and mat member according to the present invention will be described below with reference to the drawings. However, the present invention is not limited to this embodiment, and various modifications and improvements can be made based on the knowledge of those skilled in the art.

[0020] (Mat Member) As shown in FIGS. 1 and 2 , the mat member 10 is formed by arranging a plurality of cushion members 20, 30. The mat member 10 can be, for example, a mattress, and is used as bedding for use on a bed or under a futon. The mat member 10 is set to a size (area) large enough for a person to sleep on. The mat member 10 has a length (front-to-back length) of 1800 to 2200 mm, a width (left-to-right length) of 850 to 2000 mm, and a height (thickness) of 30 to 400 mm. In this embodiment, for example, the length is 1970 mm, the width is 960 mm, and the height (thickness) is 52 mm.

[0021] The mat member 10 includes a lower mat 11 serving as a base, and an upper mat 15 stacked (placed) on the upper surface of the lower mat 11. The upper mat 15 includes a first section mat 12, a second section mat 13, and a third section mat 14 arranged side by side. In this embodiment, the first section mat 12 and the second section mat 13 are formed of the cushion member 20 according to the present invention. The third section mat 14 is formed of a conventional cushion member 30. The first section mat 12, the second section mat 13, and the third section mat 14 can be referred to as upper mats 15 stacked on the lower mat 11. Note that in the present invention, the upper mat 15 does not have to be divided into three sections.

[0022] In this embodiment, the upper mat 15 is formed of three zone mats (so-called three sheets), but is not limited to this and may be formed of one zone mat (so-called one sheet), or may be formed of two or four or more zone mats. Also, in this embodiment, the mat member 10 is formed of two layers, the lower mat 11 and the upper mat 15, but the lower mat 11 may be omitted and the mat member 10 may be formed of only one layer (single layer) of the upper mat 15, or may be formed of multiple layers (multilayer) including at least the upper mat 15.

[0023] If the upper mat 15 is formed as a single piece, the upper mat 15 may be divided into ranges corresponding to the above-mentioned regions. That is, in the single piece of the upper mat 15, the presence or absence of small elastic bodies, the shape of the small elastic bodies, the thickness and hardness of the small elastic bodies, etc., which will be described later, may be varied for each range.

[0024] The lower mat 11 is formed into a predetermined shape from an elastic material. The elastic material is a material that has the property (elasticity) of deforming when an external force is applied but returning to its original shape when the external force is removed. Examples of elastic materials include foamed synthetic resin, rubber, and synthetic resin. Preferred foamed synthetic resins include soft polyurethane foam, hard polyurethane foam, polystyrene foam, polyethylene foam, polypropylene foam, EVA (ethylene vinyl acetate copolymer) crosslinked foam, PET (polyethylene terephthalate) resin foam, phenol foam, silicone foam, polyvinyl chloride foam, acrylic foam, polyimide foam, and EPDM (ethylene propylene diene rubber) foam.

[0025] As the rubber, it is preferable to use natural rubber (NR), epoxidized natural rubber (ENR), or synthetic rubber such as ethylene propylene diene rubber (EPDM), styrene butadiene rubber (SBR), nitrile rubber (NBR), butadiene rubber (BR), butyl rubber (isobutylene-isoprene rubber) (IIR), acrylic rubber (ACM), silicone rubber (SR), or fluororubber. As the synthetic resin, it is preferable to use a dynamically crosslinked (vulcanized) thermoplastic elastomer (TPV), but thermoplastic resin, thermosetting resin, or the like may also be used. Note that the dynamically crosslinked thermoplastic elastomer is produced by melt-kneading a thermoplastic resin and rubber to crosslink the rubber in the thermoplastic resin matrix.

[0026] The predetermined shape is preferably a square shape in a plan view, but may also be a polygonal shape such as a triangle or pentagon. The length and width of the lower mat 11 are set to be the same as the length and width of the mat member 10, respectively.

[0027] The height (thickness) of the lower mat 11 is preferably set to 5 mm to 380 mm, and is set to 15 mm to 17 mm in this embodiment. On the other hand, the height (thickness) of the upper mat 15 is usually set to 5 mm to 150 mm, but can also be set to 100 mm, 200 mm, or 400 mm (single layer), and is set to 35 mm in this embodiment.

[0028] The thickness of both the lower mat 11 and the upper mat 15 can be set arbitrarily within the range of the thickness of the mat member 10 (30 to 400 mm in this embodiment, as described above). The lower mat 11 can also be omitted. In this case, the mat member 10 is a single layer formed only by the upper mat 15. That is, the height (thickness) of the lower mat 11 can be set within a range of 0% to less than 100% of the height (thickness) of the mat member 10, and the height (thickness) of the upper mat 15 can be set within a range of more than 0% to 100% of the height (thickness) of the mat member 10. The thickness of the lower mat 11 is preferably set within a range of 19 / 20 or less of the height (thickness) of the mat member 10, and in this embodiment, it is set to approximately 1 / 3. On the other hand, the thickness of the upper mat 15 is preferably set within a range of 1 / 20 or more of the height (thickness) of the mat member 10, and in this embodiment, it is set to approximately 2 / 3.

[0029] (Mat for First Zone, Mat for Second Zone, Mat for Third Zone) The mat for first zone 12 is the mat member in the zone closest to the head when the mat member 10 is divided into multiple zones. The mat for first zone 12 is a mat member that supports at least the head and shoulders. The mat for first zone 12 is divided in the left-right direction and has a left mat for first zone 12a and a right mat for first zone 12b. The left mat for first zone 12a and the right mat for first zone 12b are formed symmetrically.

[0030] The width (length in the left-right direction) of the first section mat 12 is set to be the same as the width of the lower mat 11. The widths (length in the left-right direction) of the first section left mat 12a and the first section right mat 12b are set to be the same and are set to be 1 / 2 the width of the lower mat 11. The length (length in the front-rear direction) of the first section mat 12 is set to be 1 / 3 the length of the lower mat 11.

[0031] The second section mat 13 is a mat member in the section located in the center in the front-to-rear direction when the mat member 10 is divided into multiple sections. The second section mat 13 is a mat member that supports at least the lower back and buttocks. The second section mat 13 is divided in the left-right direction and has a second section left mat 13a and a second section right mat 13b. The second section left mat 13a and the second section right mat 13b are formed symmetrically.

[0032] The width (left-right length) of the second section mat 13 is set to be the same as the width of the lower mat 11. The widths (left-right length) of the second section left mat 13a and the second section right mat 13b are set to be the same and are set to be 1 / 2 the width of the lower mat 11. The length (front-rear length) of the second section mat 13 is set to be 1 / 3 the length of the lower mat 11.

[0033] The third section mat 14 is the mat member in the section closest to the feet when the mat member 10 is divided into multiple sections. The third section mat 14 is a mat member that supports at least the feet. The width (left-right length) of the third section mat 14 is set to be the same as the width of the lower mat 11. The length (front-rear length) of the third section mat 14 is set to be one-third the length of the lower mat 11. The height (thickness) of each of the above-mentioned section mats 12, 13, 14 is set to be the same as that of the upper mat 15.

[0034] Like the lower mat 11, each of the zone mats 12, 13, and 14 is formed into a predetermined shape from an elastic material. The hardness of each zone mat 12, 13, and 14 is preferably set to a hardness corresponding to the part of the body it supports. The hardness of the first zone mat 12, which supports the head, and the hardness of the third zone mat 14, which supports the feet, are preferably set to be softer than the hardness of the second zone mat 13, which supports the buttocks.

[0035] For example, the hardness of the mat 12 for the first section, the hardness of the mat 13 for the second section, and the hardness of the mat 14 for the third section are set to normal, firm, and normal, respectively. Also, the hardness of the mat 12 for the first section, the hardness of the mat 13 for the second section, and the hardness of the mat 14 for the third section are set to firm, extra firm, and firm, respectively, or soft, normal, and soft, etc.

[0036] The hardness of the first region is preferably 60 to 180 N, the hardness of the second region is preferably 70 to 200 N, and the hardness of the third region is preferably 60 to 180 N. The second region is preferably harder than the first region, and the second region is preferably harder than the third region.

[0037] Here, hardness is a magnitude indicated by a numerical value obtained by the hardness test measurement method specified in JIS K6400-2 (Flexible foam materials - Physical properties - Part 2: Method for determining hardness and compressive stress-strain characteristics), 6.4 "Method A (method for determining the force after 30 seconds of constant 40% compression)." For example, "soft" is less than 75 N (Newtons), "normal" is 75 N or more but less than 110 N, "slightly firm" is 110 N or more but less than 140 N, "firm" is 140 N or more but less than 170 N, and "ultra-firm" is 170 N or more.

[0038] In this embodiment, the first and second zone mats 12, 13 are formed using the cushion member 20 according to the present invention, and the third zone mat 14 is formed using a regular cushion member 30 without the small elastic bodies 22a. However, this is not limited to this, and each zone mat 12, 13, 14 (even when multiple zone mats are used) only needs to include at least one cushion member 20 according to the present invention, and the zone mats 12, 13, 14 can be combined as desired. It is preferable that the combination be appropriately determined according to the user's preference for firmness (taste), body type, and functionality (ease of turning over, sleeping position, sleeping comfort, and body pressure distribution).

[0039] The hardness of each of the zone mats 12, 13, and 14 (even when multiple zone mats are used) can be adjusted by changing the material of the elastic material, the manufacturing method, or by changing the shape, spacing, and area of ​​the small elastic bodies defined by the slits, as described below. For example, the same slit shape can be achieved by changing the material, the same material can be achieved by changing the shape of the slits, the same material and the same slit shape can be achieved by changing the size of the shape, or the slit shape and material can be changed. Changing the material includes changing the type of component (e.g., polyol) or the amount of foaming agent.

[0040] The first section mat 12, the second section mat 13, and the third section mat 14 are attached to the lower mat 11 with, for example, adhesive, double-sided tape, etc. The first section mat 12, the second section mat 13, and the third section mat 14 may also be detachably attached with hook-and-loop fasteners, etc. The first section mat 12, the second section mat 13, and the third section mat 14 do not have to be divided or separated, and may be combined into a single piece.

[0041] Although the cushion member 20 is intended to be used in a mattress (bedding), it is not limited to this and may also be used in the seat or back of a chair (including a vehicle seat), sofa, or other seat on which a person sits.

[0042] (Cushion Member) The cushion member 20 according to the present invention is a cushion member made of an elastic material. As shown in FIGS. 4 and 5 , the cushion member 20 includes a plurality of small elastic bodies 22a partitioned by a plurality of slits Sa*, Sb* formed by intersecting with other slits Sb*, Sa*. The slits Sa*, Sb* are linear slits. The slit Sa is formed along the front-to-rear direction (the left-to-right direction in FIG. 4 ), and the accompanying "*" indicates the slit Sa number along the left-to-right direction (the up-to-down direction in FIG. 4 ). The slit Sa1 indicates the rightmost slit, and the slits Sa are numbered in ascending order as one moves leftward. The slit Sb is formed along the left-to-right direction, and the accompanying "*" indicates the slit Sb numbered in the front-to-rear direction. The slit Sb1 indicates the frontmost slit, and the slits Sb are numbered in ascending order as one moves rearward.

[0043] 4, the cushion member 20 includes a frame portion 21 and a small elastic body portion 22 having a plurality of small elastic bodies 22a. The cushion member 20 has slits Sa* and Sb* on the surface side that can be touched by a person. The cushion member 20 may be a single-layer product as in this embodiment, or a multi-layer product (laminate product).

[0044] The frame portion 21 forms the outer frame of the cushion member 20 and supports the small elastic body portion 22 disposed inside the frame portion 21. The frame portion 21 also functions as the outer frame of the mat member 10. Therefore, the frame portion 21 is formed at the end portion located on the outer edge of the mat member 10, but is not formed at the end portion located on the inner edge of the mat member 10. For example, in the right mat 12b for the first zone shown in FIG. 4, the frame portion 21 is formed in an L-shape in a plan view and has a right-end frame portion 21a formed at the right end and a front-end frame portion 21b formed at the front end. The front end of the right-end frame portion 21a is integrally connected to the right end of the front-end frame portion 21b. Note that, in this embodiment, the frame portion 21 is not formed at the end portion located on the inner edge of the mat member 10, but this is not limited thereto, and the frame portion 21 may also be formed at the end portion located on the inner edge of the mat member 10.

[0045] The small elastic body 22a is partitioned by a plurality of gaps Sa*, Sb* that intersect with other gaps. For example, as shown in Figures 4 and 5, the small elastic body 22a (6,6) among the small elastic bodies 22a is partitioned by gaps Sa6-6, Sa7-6, Sb6-6, and Sb7-6. Gap Sa6-6 intersects with gaps Sb6-6 and Sb7-6, and gap Sa7-6 intersects with gaps Sb6-6 and Sb7-6. Gap Sa6-6 and gap Sb6-6 intersect at intersection P(5,5), and gap Sa6-6 and gap Sb7-6 intersect at intersection P(6,5). The gap Sa7-6 and the gap Sb6-6 intersect at the intersection P(5,6), and the gap Sa7-6 and the gap Sb7-6 intersect at the intersection P(6,6).

[0046] The small elastic body 22a (α, β) indicates its position relative to the reference small elastic body 22a (1, 1), where α indicates the position (number) in the front-to-back direction (left-to-right direction in FIG. 4), and β indicates the position in the left-to-right direction (up-to-down direction in FIG. 4). The gap Saγ-δ or Sbγ-δ indicates the position of the γ-th gap Sa* from the reference (right-end frame portion), and δ indicates the position (number) from the reference (front-end frame portion). The intersection P (x, y) indicates its position relative to the reference origin P (0, 0), where x indicates the position (number) in the front-to-back direction (left-to-right direction in FIG. 4), and y indicates the position in the left-to-right direction (up-to-down direction in FIG. 4).

[0047] The width of the slit Sa* and the slit Sb* is set to be greater than 0 mm, and is preferably set to, for example, 5 mm or less, 3 mm or less, or 2 mm or less. The depth of the slit Sa* and the slit Sb* is preferably set to a constant value from the surface of the cushion member 20 in the thickness direction. The depth of the slit Sa* and the slit Sb* is preferably set to, for example, a range from 5 mm to the thickness of the cushion member 20, and is preferably set to a depth range of, for example, 10% or more, 25% or more, 50% or more, 75% or more, to 100% of the thickness of the cushion member 20. In this embodiment, the depth of the slit Sa* and the slit Sb* is set to be the same as the thickness (height) of the cushion member 20. That is, the slit Sa* and the slit Sb* are formed so as to penetrate the cushion member 20 in the thickness (height) direction.

[0048] In this specification, the mat member may include a lower mat 11 and an upper mat 15. When the lower mat 11 and the upper mat 15 are bonded (integrated), the slit can be set to a depth that is 100% of the thickness of the cushion member 20 (the same value as the thickness of the cushion member 20). Even if the small elastic bodies are separated from each other by the slit, each small elastic body remains bonded to the lower mat 11. On the other hand, the mat member may not include the lower mat 11 and only include the upper mat 15. In this case, it is preferable to set the slit to a value that is less than 100% of the thickness of the cushion member 20 (a value that is not the same as the thickness of the cushion member 20). This is because, even if the small elastic bodies are separated from each other by the slit, the small elastic bodies are connected by the connecting parts to prevent them from coming apart. The thickness of the connecting parts, described below, can also be set using the same concept.

[0049] In this embodiment, the slit shape (linear shape) that forms the small elastic body 22a is a square shape formed by slit Sa6-6, slit Sa7-6, slit Sb6-6, and slit Sb7-6. Therefore, the slit shape may be referred to as a square shape. Furthermore, the slit shape that forms the small elastic body is not limited to a square shape, and may be formed into other quadrangular shapes (rectangle, diamond, etc.), circular, elliptical, polygonal (triangle, pentagon, hexagon, etc.), or other shapes. The slit may be linear or curved, and any shape is acceptable as long as it is a line segment with two intersections at both ends.

[0050] In this embodiment, the gaps Sa6-5, Sa6-6, Sb6-5, and Sb6-6 intersect at 90 degrees at the intersection P(5,5). That is, a plurality of gaps intersect at the intersection at a predetermined angle.

[0051] The small elastic bodies 22a are adjacent to adjacent members via the cuts Sa* and Sb*. The small elastic bodies 22a are connected to the adjacent members by connecting portions 23 and 24. The adjacent members include the small elastic bodies 22a and the frame portion 21. The connecting portions 23 connect the small elastic bodies 22a to the frame portion 21, and the connecting portions 24 connect the small elastic bodies 22a to each other.

[0052] As shown in FIG. 5 , the connecting portion 24 is formed between two adjacent points P, P among the intersection points P where the gap Sa* and the gap Sb* intersect. In this embodiment, the connecting portion 24 is disposed at the midpoint of a line segment having the two adjacent points P, P as its ends. Like the connecting portion 24, the connecting portion 23 is disposed at the midpoint of the two adjacent points P, P. The connecting portions 23, 24 are disposed on the gap Sa* or Sb* connecting the two adjacent points P, P. The connecting portions 23, 24 are formed as cutting portions that separate the gap Sa* or the gap Sb*. Note that in this embodiment, the connecting portions 23, 24 are disposed at the midpoint of the two points P, P, but are not limited to this and may be disposed at any position between the two adjacent points P, P.

[0053] The length of the connecting portions 23, 24 (the length along the extending direction of the slit) is preferably set shorter than the length of the slit Sa* or Sb* between adjacent connecting portions 23 (or 24), and is preferably set to, for example, 20 mm or less, 15 mm or less, and more preferably 10 mm or less, 5 mm or less. Furthermore, the connecting portions 23, 24 are formed to extend along the thickness direction of the cushion member 20. In this embodiment, when the connecting portions 23, 24 are set in the thickness direction of the cushion member 20, the depth (length in the thickness direction) of the connecting portions 23, 24 is preferably set to, for example, 25% or more, 50% or more, or 75% or more of the thickness of the cushion member 20. When the lower mat 11 serving as the base is stacked, the depth can be set to 0%, and is preferably set to the same thickness as the lower mat 11.

[0054] The small elastic bodies 22a are formed in a columnar shape with a rectangular (square) surface. The surface of the small elastic bodies 22a can support the human body. The surface of the small elastic bodies 22a can independently support the body parts that come into contact with the surface. In this way, the small elastic bodies 22a can independently support each body part of the human body, and can generate compressive deformation according to the distribution of body weight (load). As a result, the cushion member 20, and in turn the mattress member 10, can improve body pressure distribution, sleeping comfort, and turning ability.

[0055] The surface area of ​​each small elastic body 22a partitioned by the cut is 0.04 cm ２ (4 mm ２ ) to 450 cm ２ (45,000 mm ２ ) is preferably set in the range of, for example, 8 cm ２ More than 15cm ２ Above, 20cm ２ More than 300 cm is preferable. ２ Below, 150cm ２ Below, 80cm ２ Below, 50cm ２ In this embodiment, the surface area of ​​the small elastic body 22a is preferably 25 cm or less. ２ (2500 mm ２ ) is set.

[0056] Furthermore, when the cushion member 20 is made of the same material, the larger the surface area of ​​each small elastic body 22a separated by the slits, the greater the resistance of the cushion member 20 when turning over. In other words, the smaller the surface area of ​​the small elastic body 22a, the lower the resistance of the cushion member 20 when turning over. This is for the following reason. Because the small elastic bodies 22a are separated from adjacent portions by slits, even if they are only slightly connected, they can deform independently of other small elastic bodies when stress is applied. Therefore, when compressing the small elastic bodies 22a, the smaller the surface area of ​​the small elastic bodies 22a, the less force is required for compression. In other words, when turning over, the small elastic bodies 22a are compressed by the rotation of the body, so the smaller the surface area of ​​the small elastic bodies 22a, the less force is required for compression, i.e., the less resistance is required when turning over. As a result, by reducing the resistance when turning over, it is possible to improve the ease of turning over.

[0057] Furthermore, the smaller the surface area of ​​the small elastic bodies 22a, the more they can contact the shape of the body, increasing the contact area (contact region) with the body, i.e., the area that receives the body load, making it possible to reduce the load per unit area and the amount of sinking. In this way, it is possible to improve the body pressure distribution of the cushion member 20. Furthermore, even if the surface shapes of the small elastic bodies 22a are the same (similar shapes), the smaller the surface area of ​​the small elastic bodies 22a, the less resistance there is when turning over in bed and the smaller the load per unit area, making it possible to improve the ability to turn over in bed and the body pressure distribution.

[0058] The small elastic bodies 22a are connected to adjacent members via connecting portions 23, 24 at the midpoints of each side. The small elastic bodies 22a can move in conjunction with the adjacent members connected via the connecting portions 23, 24. That is, because the connecting portions 23, 24 are elastic, when a force is applied from above to the surface of one small elastic body 22a, the small elastic body 22a is compressed in the vertical direction. The connecting portions 23, 24 are also compressed along with the compression, but the upper portions of the connecting portions 23, 24 are stretched and pulled downward. Even if the surface of the small elastic body 22a to which the force is applied is pressed down, the surface of the small elastic body 22a adjacent to that small elastic body 22a is not pressed down simultaneously, but is pressed down with a delay due to the stretching of the connecting portions 23, 24. In this way, the small elastic bodies 22a can operate independently under certain conditions.

[0059] Since adjacent small elastic bodies 22a are adjacent to each other via the slits Sa* and Sb*, when a force is applied from above to one small elastic body 22a, even if that small elastic body 22a tilts sideways, it will come into contact with and be supported by the small elastic body 22a adjacent to it, making it possible to minimize the tilting of that small elastic body 22a to at least the width of the slits Sa* and Sb*. As a result, the cushion member 20 and therefore the mat member 10 can reliably support the body and prevent the body from sinking excessively.

[0060] The cuts are preferably formed on the surface of the cushion member by groove processing using a contour blade or a reciprocating saw, or slit processing using a Thomson blade. Furthermore, the connecting portions are preferably formed by notches in accordance with the shape of the connecting portions provided on the Thomson blade.

[0061] (Variation 1: Placing connecting portions at intersections) In the present embodiment, connecting portions 23, 24 are formed between two adjacent points P, P among multiple intersections P where slit Sa* and slit Sb* intersect, but the present invention is not limited to this, and connecting portion 124 may be formed at an intersection P where slit Sa* and slit Sb* intersect, as shown in Fig. 6. Connecting portion 124 is formed as a cutting portion that cuts off slit Sa* or slit Sb* at the intersection where slit Sa* and slit Sb* intersect.

[0062] The small elastic body 122a is divided by a plurality of gaps Sa*, Sb* that intersect with other gaps. For example, as shown in FIG. 6, the small elastic body 122a (6, 6) among the small elastic bodies 122a is divided by gaps Sa6-6, Sa7-6, Sb6-6, and Sb7-6, similar to the small elastic body 22a described above. The gap shape, which is the shape (linear shape) of the gaps that form the small elastic body 122a, is a quadrangular shape (e.g., a square shape) formed by gaps Sa6-6, Sa7-6, Sb6-6, and Sb7-6.

[0063] Gap Sa6-6 and gap Sb6-6 intersect at intersection P(5,5), and gap Sa6-6 and gap Sb7-6 intersect at intersection P(6,5). Gap Sa7-6 and gap Sb6-6 intersect at intersection P(5,6), and gap Sa7-6 and gap Sb7-6 intersect at intersection P(6,6). Similar to the above-described connecting portion 24, connecting portions 124 are formed at each of these intersections P(5,5), P(6,5), P(5,6), and P(6,6). In this case as well, multiple gaps intersect at a predetermined angle at the intersections.

[0064] According to this first modification, the small elastic bodies 122a have surfaces of the same shape and size as the small elastic bodies 22a of the above-described embodiment, and the connecting portions 124 are located at the vertices of the small elastic bodies 122a. In other words, the connecting portions 124 connect four adjacent small elastic bodies 122a. As a result, it is possible to improve the connectivity (interlocking) of each small elastic body 122a compared to a case where there are fewer connecting portions. Furthermore, even if the same force acts on a single small elastic body and it is compressed and deformed, the more small elastic bodies (connecting portions) that are connected, the greater the force that prevents compression (the pulling force), and the less it sinks.

[0065] In this way, even if small elastic bodies have surfaces of the same shape and size, by changing the connecting manner (location and number of connecting parts), it is possible to adjust the amount of sinking of the small elastic bodies, thereby adjusting body pressure distribution and ultimately improving body pressure distribution. In other words, by setting the connecting manner of the mat member according to the body part supported by the small elastic bodies, it is possible to support the body appropriately and to allow compressive deformation according to the body weight distribution.

[0066] (Variant 2: The cuts have a predetermined continuous linear shape, and the connecting portion is located at the back side end in the thickness direction) Furthermore, in the above-described embodiment or variant 1, the small elastic bodies 22a, 122a were separated by cuts Saγ-δ and Sbγ-δ, which have intermittent linear shapes, but in variant 2, the small elastic bodies 222a are separated by cuts Sa* and Sb*, which have a predetermined continuous linear shape (straight line).

[0067] 7, the mat member 210 according to this modified example 2, like the mat member 10 described above, has a lower mat 11, and a first section mat 212, a second section mat 213, and a third section mat 14 arranged on the upper surface of the lower mat 11. In this modified example 2, the first section mat 212 and the second section mat 213 are formed from the cushion member 220 according to the present invention.

[0068] (Mat for first section, mat for second section, mat for third section) The mat for first section 212 is a mat member similar to the mat for first section 12 described above, and has a left mat for first section 212 a and a right mat for first section 212 b. The mat for second section 213 is a mat member similar to the mat for second section 13 described above, and has a left mat for second section 213 a and a right mat for second section 213 b.

[0069] (Cushion Member) The cushion member 220 according to the present invention is a cushion member formed of the same elastic material as the cushion member 20 described above. As shown in Fig. 8, the cushion member 220 includes a plurality of small elastic bodies 222a partitioned by a plurality of slits Saa*, Sba* formed by intersecting with other slits Sba*, Saa*. The slits Saa*, Sba* are slits formed in a continuous straight line (without any cut portions).

[0070] 8, the cushion member 220 includes a frame portion 21 and a small elastic body portion 222 having a plurality of small elastic bodies 222a. The cushion member 220 has slits Saa* and Sba* on the surface side that can be touched by a person.

[0071] The small elastic body 222a is divided by a plurality of gaps Saa*, Sba* formed by intersecting with other gaps. For example, as shown in FIG. 8, the small elastic body 222a (6,6) among the small elastic bodies 222a is divided by gaps Saa6, Saa7, Sba6, and Sba7. Gap Saa6 intersects with gaps Sba6 and Sba7, and gap Saa7 ​​intersects with gaps Sba6 and Sba7. Gap Saa6 and gap Sba6 intersect at intersection P(5,5), and gap Saa6 and gap Sba7 intersect at intersection P(6,5). The gap Saa7 ​​and the gap Sba6 intersect at an intersection P(5,6), and the gap Saa7 ​​and the gap Sba7 intersect at an intersection P(6,6).

[0072] In addition, the small elastic body 222a (α, β) indicates its position relative to the reference small elastic body 222a (1, 1), where α indicates the position (number) in the front-to-back direction (left-to-right direction in Figure 8) and β indicates the position in the left-to-right direction (up-down direction in Figure 8).

[0073] The widths of the slits Saa* and Sba* are set to be greater than 0 mm, and are preferably set to, for example, 5 mm or less, 3 mm or less, or 2 mm or less. The depths of the slits Saa* and Sba* are preferably set to a constant value in the thickness direction from the surface of the cushion member 220. The depths of the slits Saa* and Sba* are preferably set to, for example, a range from 5 mm to the thickness of the cushion member 220, and are preferably set to a depth range of, for example, 10% or more, 25% or more, 50% or more, 75% or more, to 100% of the thickness of the cushion member 220. In this embodiment, the depths of the slits Saa* and Sba* are set to half the thickness of the cushion member 220. That is, the slits Saa* and Sba* do not penetrate the cushion member 220 in the thickness (height) direction, and the thickness-wise rear end portions of the slits Saa* and Sba* have connecting portions 223 and 224 (described later) formed in the remaining portion of the depth (thickness direction) of the slits. Therefore, the depth (thickness direction length) of the connecting portions 223 and 224 is preferably set to, for example, 25% or more, 50% or more, or 75% or more of the thickness of the cushion member 200. Furthermore, in this modified example 2, the slits Saa6 and Sba6 intersect at an angle of 90 degrees at an intersection P(5,5). That is, multiple slits intersect at a predetermined angle at the intersection.

[0074] The small elastic body 222a is adjacent to an adjacent member via a cut Saa* or Sba*. The small elastic body 222a is connected to the adjacent member by a connecting portion 223 or 224. The adjacent member can be the small elastic body 222a or the frame portion 21. The connecting portion 223 connects the small elastic body 222a to the frame portion 21, and the connecting portion 224 connects the small elastic bodies 222a to each other.

[0075] In the above-described embodiment or variant 1, the connecting portions 23, 24, and 124 are provided along the entire thickness direction of the cushion member 20 (to the same thickness as the entire thickness direction length of the cushion member 20). However, the connecting portions 223 and 224 according to variant 2 connect the small elastic body 222a to an adjacent member at the rear end of the cushion member 220 in the thickness direction. In other words, the connecting portions 223 and 224 are formed along the entire length of the slits Saa* and Sba* at the rear end of the slits Saa* and Sba* in the thickness direction, along the direction in which the slits Saa* and Sba* extend. The lengths of the connecting portions 223 and 224 (the lengths along the direction in which the slits extend) are preferably provided continuously, similar to the slits Saa* and Sba*, and are set to the same length as the slits Saa* and Sba*. The connecting portions 223 and 224 are not limited to being formed continuously, but may be formed intermittently. Furthermore, it is preferable that the connecting portions 223 and 224 are formed so as to extend along the thickness direction of the cushion member 220 .

[0076] Similar to the small elastic body 22a described above, the small elastic body 222a is formed in a columnar shape with a rectangular (square) surface. The small elastic body 222a is connected to an adjacent member at the rear end in the thickness direction of the cushion member 220 via connecting portions 223 and 224. In other words, the front side of the small elastic body 222a in the thickness direction of the cushion member 220 is not connected to an adjacent member, and the small elastic body 222a can operate more independently than the small elastic body 22a described above.

[0077] Furthermore, because adjacent small elastic bodies 222a are adjacent to each other via the slits Saa* and Sba*, when a force is applied from above to one small elastic body 222a, even if that small elastic body 222a tilts sideways, it will come into contact with and be supported by the small elastic body 222a adjacent to it, making it possible to minimize the tilting of that small elastic body 222a to at least the width of the slits Saa* and Sba*. As a result, the cushion member 220 and therefore the mat member 210 can reliably support the body and prevent the body from sinking excessively.

[0078] In the cushion member 220 described above, the cuts Saa* and Sba* are cuts formed in a continuous straight line, but are not limited to a straight line, and may be formed in a curved line or any other desired shape as long as they are formed in a predetermined shape.

[0079] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples and can be practiced in various forms with various modifications and improvements based on the knowledge of those skilled in the art.

[0080]

[0081] In the examples, mat members 210 of the first type TYPE 1 to the fifth type TYPE 5 are used. As shown in Table 1, in the first type TYPE 1, the hardness of the lower mat 11 (which may also be referred to as the hardness of the material of the lower mat 11) is 170N, and the mat 212 for the first zone uses a cushion member 220 with a slit and has a hardness of 120N. The mat 213 for the second zone uses a cushion member 220 with a slit and has a hardness of 170N, and the mat 14 for the third zone uses a flat cushion member 30 without a slit and has a hardness of 120N. Note that each mat with a slit in Table 1 is 25cm long. ２ The square cut is provided over the entire thickness and depth of the cushion member.

[0082] In the second type TYPE2, the lower mat 11 has a hardness of 120N, the first zone mat 212 employs a cushion member 220 with a slit and has a hardness of 80N, the second zone mat 213 employs a cushion member 220 with a slit and has a hardness of 120N, and the third zone mat 14 employs a flat cushion member 30 without a slit and has a hardness of 80N.

[0083] In the third type TYPE 3, the lower mat 11 has a hardness of 120 N, the first zone mat 212 employs a cushion member 220 with a slit and has a hardness of 120 N. The second zone mat 213 employs a cushion member 220 with a slit and has a hardness of 120 N, and the third zone mat 14 employs a flat cushion member 30 without a slit and has a hardness of 120 N.

[0084] In the fourth type TYPE 4, the lower mat 11 has a hardness of 170 N, the first zone mat 212 employs a cushion member 220 with a slit and has a hardness of 120 N. The second zone mat 213 employs a flat cushion member 30 without a slit and has a hardness of 120 N, and the third zone mat 14 employs a cushion member 220 with a slit and has a hardness of 120 N.

[0085] In the fifth type TYPE 5, the lower mat 11 has a hardness of 120 N, the first zone mat 212 employs a cushion member 220 with a slit and has a hardness of 120 N. The second zone mat 213 employs a flat cushion member 30 without a slit and has a hardness of 120 N, and the third zone mat 14 employs a cushion member 220 with a slit and has a hardness of 120 N.

[0086]

[0087] Furthermore, the mat members of Examples 1 to 5 were made using the cushion member 220 shown in Table 2. Furthermore, the mat members of Comparative Examples 2 to 6 were made using the cushion member 30 (flat, without cuts) shown in Table 1. Comparative Example 1 is a corrugated mat member made of urethane foam, known as a corrugated mattress.

[0088] In the mat member of Example 1, the upper layer is formed of a cushion member 220 having a slit on the surface, and the lower layer is formed of a lower mat 11, and the hardness of the upper and lower layers is 170 N. In the mat members of Examples 2 to 5, the upper and lower layers are formed in the same manner as in Example 1. The hardness of the upper and lower layers of Example 2 is 120 N and 170 N, respectively, the hardness of the upper and lower layers of Example 3 is 120 N, the hardness of the upper and lower layers of Example 4 is 80 N and 120 N, respectively, and the hardness of the upper and lower layers of Example 5 is 80 N.

[0089] In the mat member of Comparative Example 2, the upper layer is formed of a flat cushion member 30 with no gaps on the surface, and the lower layer is formed of a lower mat 11, with the hardness of the upper and lower layers being 170 N. In the mat members of Comparative Examples 3 to 6, the upper and lower layers are formed similarly to Comparative Example 2. The hardnesses of the upper and lower layers of Comparative Example 3 are 120 N and 170 N, respectively, the hardnesses of the upper and lower layers of Comparative Example 4 are 120 N, the hardnesses of the upper and lower layers of Comparative Example 5 are 80 N and 120 N, respectively, and the hardnesses of the upper and lower layers of Comparative Example 6 are 80 N. Comparative Examples 2 to 6 differ from Examples 1 to 5 only in the presence or absence of gaps in the upper layer, but the hardnesses of the upper and lower layers are the same. The hardness of the mat member of Comparative Example 1 is 270 N.

[0090] The mat members of Examples 1 to 5 and the mat members of Comparative Examples 1 to 6 were evaluated for their ability to turn over in bed. Specifically, a pressure element corresponding to the lower back of the body was used to measure the tension when the pressure element was swung, and the measured tension was evaluated as the resistance applied to the body when turning over in bed. The pressure element is a tool that can be used in the hardness test measurement method specified in JIS K6400-2 mentioned above.

[0091] In evaluating the ability to turn over, the greater the resistance (stress) exerted on the body when turning over, the more difficult it is to turn over, and therefore the greater the measured tension, the worse the ability to turn over. The tension when a JIS K6400-2 hardness measuring pressure probe is placed on the surface of the cushion member and pulled horizontally is, for example, 20.5 N or less, preferably 20 N or less, more preferably 19.5 N or less, more preferably 19 N, and even more preferably 18.5 N or less. As is clear from Table 2, when the cushion member 220 has the above-described slits (Examples 1 to 5), the tension and resistance can be reduced compared to when there are no slits (Comparative Examples 2 to 6), thereby improving the ability to turn over. When the cushion member 220 has the above-described slits (Examples 1 to 5), the tension and resistance can be reduced compared to the wavy mattress (Comparative Example 1), thereby improving the ability to turn over.

[0092] Furthermore, the mattress members 210 of the first type TYPE 1 to the fifth type TYPE 5 were evaluated for sleeping posture. The sleeping posture was evaluated based on the measurement results, measuring the amount of sinking of a specific part of the body when a person actually lies on the mattress member in a supine position. For example, the gap of the S-shaped curve of the lower back can be used as the amount of sinking.

[0093] Sleeping posture is evaluated based on the amount of strain placed on the body while lying down, with the lower back being evaluated as a higher sleeping posture. Furthermore, when the gap in the S-shaped curve of the lower back is 15 to 35 mm, especially 20 to 30 mm, the strain on the body is low, and when the gap is smaller or larger than this range, the strain on the body increases.

[0094]

[0095] As is clear from Table 3, the amounts of sinking for Comparative Example 11 (spring mattress), Comparative Example 12 (flat-type urethane foam mat with no seams on the surface), and Comparative Example 13 (mat member of the corrugated mattress described above) are 25 mm, 40 mm, and 30 mm, respectively. The sleeping posture evaluations for Comparative Examples 11 and 12 were poor, while the evaluation for Comparative Example 13 was good. On the other hand, the amounts of sinking for the first type TYPE 1 to the fifth type TYPE 5, which are examples, are 28 mm, 30 mm, 30 mm, 30 mm, and 30 mm, respectively. For the first type TYPE 1 to the fifth type TYPE 5, which are examples, the amounts of sinking are in the range of 15 to 35 mm, particularly 20 to 30 mm, so the sleeping posture evaluation is good.

[0096] Furthermore, the first type TYPE 1 mattress member 210 was evaluated for its body pressure distribution. Regarding body pressure distribution, a person actually lay on the mattress member in the supine and lateral positions, and the load (pressure) at the contact area and each point on that contact area was measured using a surface pressure measuring device or the like, and the evaluation was based on the measurement results. The test subject was a woman with a BMI (body mass index: calculated by dividing body weight (kg) by the square of height (m)) of approximately 23.6. A sensor for measuring the in-plane pressure distribution was placed on the test mattress, and the test subject was laid on the mattress, and the pressure distribution, etc. was measured using the sensor.

[0097]

[0098] As is clear from Table 4, for Comparative Example 11 (the spring mat described above) and Comparative Example 13 (the mat member of the corrugated mattress described above), the average pressure, peak pressure (maximum pressure), and contact area in the supine position were each 0.31 N / cm ２ , 1.50 N / cm ２ , 2371 cm ２ , and 0.30 N / cm ２ , 1.07 N / cm ２ , 2523 cm ２ In addition, the mean pressure, peak pressure, and contact area in the lateral position were 0.38 N / cm ２ , 1.85 N / cm ２ , 1984cm ２ , and 0.36 N / cm２ , 1.32 N / cm ２ , 2103 cm ２ is.

[0099] On the other hand, for the first type TYPE 1, which is an example, the mean pressure, peak pressure, and contact area in the supine position are 0.30 N / cm ２ , 0.71 N / cm ２ , 2784 cm ２ The mean pressure, peak pressure, and contact area in the lateral position are 0.37 N / cm ２ , 0.98N / cm ２ , 2465 cm ２ is.

[0100] In the supine and lateral positions, the contact area of ​​the first type TYPE 1 (Example) is larger than that of the comparative example, and although the average pressure is approximately the same, the peak pressure is suppressed to a low level. In this way, in the Example, by expanding the contact area and suppressing the peak pressure, it is possible to improve body pressure distribution.

[0101] Furthermore, Comparative Example 21 (spring mattress), Comparative Example 22 having an upper mattress 15 without slits (cuts), and Example 23 having an upper mattress 15 with slits (cuts) were evaluated for body pressure distribution in the same manner as described above. The test subject was a male with a BMI of approximately 26.0. A sensor for measuring the in-plane pressure distribution was placed on the test mattress, and the test subject lay on the mattress to measure the pressure distribution, etc. using the sensor.

[0102] The comparative example 22 without slits is a cushion member formed by stacking lower mats, the hardness of the lower mat 11 being 170N, and consisting of a mat for the first zone, a mat for the second zone, and a mat for the third zone, each of which employs a continuous flat cushion member 30. The hardness of each mat for the first zone is 120N, that for the second zone is 170N, and that for the third zone is 120N.

[0103] In addition, Example 23 with slits is a cushion member in which lower mats are laminated, and the hardness of the lower mat 11 is 170N, and a cushion member 30 is used which is composed of a mat for the first area with a slit, a mat for the second area with a slit, and a flat mat for the third area without a slit. Furthermore, the slits in Table 1 above are 25 cm ２ The square slits were provided on the entire surface of the cushion member in thickness and depth, but the slits in Table 5 marked "with slits" were regular hexagons with sides of 36 mm (area of ​​33.67 cm). ２ The hardness of each mat for the first zone is 120N, that for the second zone is 170N, and that for the third zone is 120N.

[0104]

[0105] As is clear from Table 5, for Comparative Example 21 (the above-described spring mat) and Comparative Example 22 (without slits), the average pressure, peak pressure (maximum pressure), and contact area in the supine position were 0.33 N / cm ２ , 1.81 N / cm ２ , 3996 cm ２ , and 0.35 N / cm ２ , 0.84 N / cm ２ , 4223 cm ２ In addition, for Comparative Example 21, the average pressure and contact area in the lateral position were 0.41 N / cm ２ , 3121 cm ２ The peak pressure exceeds the upper limit of measurement. Furthermore, for Comparative Example 22, the average pressure, peak pressure, and contact area in the lateral position are 0.42 N / cm ２ , 3.34 N / cm ２ , 3585 cm ２ is.

[0106] On the other hand, for Example 23 (with slits), the average pressure, peak pressure, and contact area in the supine position were 0.35 N / cm ２ , 0.72 N / cm ２ , 4385cm ２ The mean pressure, peak pressure, and contact area in the lateral position are 0.41 N / cm ２, 2.85 N / cm ２ , 3677 cm ２ is.

[0107] In the supine position, the average pressure of Example 23 (with slits) is approximately the same as that of Comparative Example 22 (without slits), but the peak pressure is slightly reduced and the contact area is slightly enlarged. In this way, in Example 23, by reducing the peak pressure and enlarging the contact area, it is possible to improve body pressure distribution. Also, in the lateral position, the average pressure of Example 23 (with slits) is approximately the same as that of Comparative Example 22 (without slits), but the peak pressure is reduced and the contact area is slightly enlarged. In this way, in Example 23, by reducing the peak pressure and enlarging the contact area, it is possible to improve body pressure distribution.

[0108] (Variations of Slit Shape) (Hexagonal) Further, variations of the slit shape will be described with reference to FIGS. 9 to 12. FIG. 9 shows a cushion member 320 employing a regular hexagon as the slit shape. The cushion member 320 includes a frame portion 21 and a small elastic body portion 322 having a plurality of small elastic bodies 322a. The small elastic bodies 322a are partitioned by a plurality of slits Sc formed by intersecting with other slits Sc. The slits Sc intersect at intersections Pc. At the intersections Pc, three slits Sc intersect. Note that the slits Sc, like the slits Sa* and Sb* described above, penetrate the cushion member 320 in the thickness direction. Adjacent small elastic bodies 322a are adjacent to each other via the slits Sc and are connected by connecting portions 324 formed on the slits Sc. Alternatively, the connecting portions may be provided at the rear end of the cushion member 320 in the thickness direction, so that the slits continue at the front end of the cushion member 320 in the thickness direction.

[0109] (Diamond) Figure 10 shows a cushion member 420 with a diamond-shaped slit. The cushion member 420 includes a frame 21 and a small elastic body portion 422 having multiple small elastic bodies 422a. The small elastic bodies 422a are defined by multiple slits Sd that intersect with other slits Sd. The slits Sd intersect at intersections Pd1 and Pd2. Three slits Sd intersect at intersection Pd1, and six slits Sd intersect at intersection Pd2. The slits Sd, like the slits Sa* and Sb* described above, penetrate the cushion member 420 in the thickness direction. Adjacent small elastic bodies 422a are adjacent to each other via the slits Sd and are connected by connecting portions 424 formed on the slits Sd. Alternatively, the connecting portions may be provided at the rear end of the cushion member 420 in the thickness direction, so that the slits continue at the front end of the cushion member 420 in the thickness direction. Furthermore, three small elastic bodies 422a are joined together with the intersection point Pd1 at the center, and these three small elastic bodies 422a form a regular hexagon.

[0110] (Hemp Leaf Pattern) FIG. 11 shows a cushion member 520 with a so-called hemp leaf pattern, in which the slits are shaped like isosceles triangles. The cushion member 520 includes a frame portion 21 and a small elastic body portion 522 having a plurality of small elastic bodies 522a. The small elastic bodies 522a are defined by a plurality of slits Se1 and Se2 formed by intersecting with other slits Se1 and Se2. Specifically, the small elastic body 522a is defined by one slit Se2 and two slits Se1. One end of slit Se1 intersects at intersection Pe1, and the other end of slit Se1 intersects at intersection Pe2. The slits Se2 intersect at intersection Pe2. Three slits Se1 intersect at intersection Pe1, and six slits Se2 and six slits Se1 intersect at intersection Pe2. The gap Se2 corresponds to the longer diagonal line of the diamond shown in FIG.

[0111] Like the above-described slits Saa* and Sba*, the slits Se1 and Se2 are formed continuously at the thickness direction front end, and the connecting portion is formed at the thickness direction back end of the cushion member 520 (the slits Se1 and Se2 do not penetrate through the thickness direction). That is, the connecting portion is provided at the thickness direction back end of the cushion member 520, and the slits Se1 and Se2 are continuous at the thickness direction front end. Adjacent small elastic bodies 522a are adjacent to each other via the slit Se1 or Se2. Furthermore, three apex angles of the small elastic body 522a are adjacent at the intersection Pe1, and these three small elastic bodies 522a form an equilateral triangle. Furthermore, twelve base angles of the small elastic body 522a are adjacent at the intersection Pe2. The cuts Se1 and Se2 may be formed so as to penetrate through in the thickness direction, and similarly to the cuts Sa and Sb, connecting portions may be formed on the cuts Se1 and Se2 along the thickness direction.

[0112] (Shippo Pattern) Figure 12 shows a cushion member 620 with a so-called Shippo pattern, in which circles or ellipses are overlapped as slit shapes. The Shippo pattern is a pattern in which quarters of identical circles or ellipses are overlapped. The cushion member 620 includes a frame portion 21 and a small elastic body portion 622 having a plurality of small elastic bodies 622a1 and 622a2. The small elastic bodies 622a1 and 622a2 are defined by a plurality of slits Sf formed by intersecting with other slits Sf. Specifically, the slits Sf are formed in the shape of a quarter arc. The small elastic body 622a1 is defined by two slits Sf. Both ends of the slits Sf intersect at an intersection Pf. Eight slits Sf intersect at the intersection Pf. Furthermore, the small elastic body 622a2 is defined by four slits Sf.

[0113] Note that, like the above-described slits Saa* and Sba*, the slit Sf is formed continuously at the thickness direction front surface end, and the connecting portion is formed at the thickness direction back surface end of the cushion member 620 (the slit Sf does not penetrate in the thickness direction). In other words, the connecting portion is provided at the thickness direction back surface end of the cushion member 620, and the slit Sf is continuous at the thickness direction front surface end. Adjacent small elastic bodies 622a1, 622a2 are adjacent to each other via the slit Sf. Note that the slit Sf may be formed penetrating in the thickness direction, and like the slits Sa and Sb, the connecting portion may be formed on the slit Sf along the thickness direction.

[0114] In the above-described mat members 10 and 210, the cushion members 20, 120, 220, 320, 420, 520, and 620 have the same linear slit shape regardless of the placement of the cushion member (i.e., regardless of the part of the body that is supported), but this is not limited thereto, and the cushion members 20, 120, 220, 320, 420, 520, and 620 may have different linear slit shapes depending on the placement of the cushion members 20, 120, 220, 320, 420, 520, and 620. For example, a cushion member with square slits may be placed in the location where the head is supported (the mat for the first zone), and a cushion member with hemp leaf pattern slits with a smaller surface area than the square slits may be placed in the location where the lumbar region is supported (the mat for the second zone).

[0115] Furthermore, in the cushion members 20, 120, 220, 320, 420, 520, and 620 described above, the same linear shape of the slits is formed regardless of the part of the person's body that the cushion member supports, but this is not limited to this, and the linear shape of the slits may be formed depending on the part of the person's body that comes into contact with the cushion members 20, 120, 220, 320, 420, 520, and 620. For example, square slits may be formed in the area that will be used to support the head, and hemp leaf pattern slits with a smaller surface area than the square slits may be formed in the area that will be used to support the lower back. Furthermore, even in the same cushion member, the linear shape of the slits may be formed in different shapes depending on the part of the person's body that comes into contact with the cushion members 20, 120, 220, 320, 420, 520, and 620.

[0116] Furthermore, in the above-mentioned mat members 10, 210, small elastic bodies having the same shape and surface area are defined regardless of the placement location of the cushion member (i.e., regardless of the part of the body they support), but this is not limited to this, and the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a may be defined by forming linear cuts so that the surface area of ​​the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a varies depending on the placement location of the cushion member 20, 120, 220, 320, 420, 520, 620. For example, in small elastic bodies formed in the same shape (e.g., square), a cushion member with a square-shaped cut with long sides and a large surface area can be placed as the cushion member (mat for the first area) placed in the area that supports the head, and a cushion member with a square-shaped cut with short sides and a small surface area can be placed as the cushion member (mat for the second area) placed in the area that supports the lower back.

[0117] Furthermore, in the cushion members 20, 120, 220, 320, 420, 520, and 620 described above, the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, and 622a are defined to have the same shape and surface area regardless of the part of the body of the person supported by the cushion member, but this is not limited to this, and the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, and 622a may be defined by forming linear slits so that the surface areas of the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, and 622a vary depending on the location on the surface of the cushion member. For example, in the same cushion member, small elastic bodies with larger surface areas may be formed in locations that will support the lower back, and small elastic bodies with smaller surface areas may be formed in locations that will support the buttocks.

[0118] (Actions and effects of the embodiment) The cushion members 20, 120, 220, 320, 420, 520, 620 according to the above-described embodiments are cushion members formed of an elastic material, and are provided with small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a that are partitioned by a plurality of slits Sa, Sb, Sc, Sd, Se1, Se2, Sf that are formed intersecting with other slits Sa, Sb, Sc, Sd, Se1, Se2, Sf.

[0119] In the cushion member 20, 120, 220, 320, 420, 520, 620 according to this embodiment, the small elastic bodies 22 a, 122 a, 222 a, 322 a, 422 a, 522 a, 622 a can each independently support the body and can undergo compressive deformation according to the weight distribution of the body. Therefore, the cushion member 20, 120, 220, 320, 420, 520, 620 can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0120] In addition, the cushion members 220, 520, 620 according to this embodiment are cushion members formed of an elastic material and include small elastic bodies 222a, 522a, 622a partitioned by continuous predetermined linear cuts Saa, Sba, Se1, Se2, Sf.

[0121] In the cushion member 220, 520, 620 according to this embodiment, the small elastic bodies 222a, 522a, 622a can each independently support the body, and can undergo compressive deformation according to the weight distribution of the body. Therefore, the cushion member 220, 520, 620 can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0122] Furthermore, in the cushion members 20, 120, 220, 320, 420, 520, 620 according to this embodiment, it is preferable that the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a are connected to adjacent members by connecting portions 23, 24, 124, 223, 224, 324, 424. With this, since the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a are connected to the adjacent members by the connecting portions 23, 24, 124, 223, 224, 324, 424, it is possible to prevent the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a from tipping over due to the load, and it is possible to achieve both compressive deformation according to the body weight distribution and prevention of tipping over. Therefore, it is possible to further improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0123] Furthermore, in the cushion members 20, 120, 220, 320, 420, 520, 620 according to this embodiment, it is preferable that the connecting portions 23, 24, 124, 223, 224, 324, 424 are formed between two adjacent points among the intersections P, Pc, Pd, Pe, Pf where the cuts Sa, Sb, Sc, Sd, Se1, Se2, Sf intersect, or at the intersections P, Pc, Pd, Pe, Pf. This makes it possible to easily form the connecting portions 23, 24, 124, 223, 224, 324, 424 along the thickness direction of the cushion members 20, 120, 220, 320, 420, 520, 620, and also makes it possible to form the connecting portions 23, 24, 124, 223, 224, 324, 424 at appropriate positions on the cuts Sa, Sb, Sc, Sd, Se1, Se2, Sf.

[0124] Furthermore, in the cushion members 220, 520, 620 according to the present embodiment, it is preferable that the cushion members 220, 520, 620 have slits Saa, Sba, Se1, Se2, Sf on the surface side that can be touched by a person, and that the connecting portions 223, 224 are connected at the rear end portions in the thickness direction of the cushion members 220, 520, 620. This allows the small elastic bodies 222a, 522a, 622a to support the body more independently and allows for compressive deformation in accordance with the body weight distribution more effectively, compared to when the connecting portions are provided along the thickness direction of the cushion member. Therefore, the cushion members 220, 520, 620 can further improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0125] Furthermore, in the cushion members 20, 120, 220, 320, 420, 520, and 620 according to this embodiment, it is preferable that the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, and 622a are partitioned by forming linear shapes of the cuts Sa, Sb, Sc, Sd, Se1, Se2, and Sf so that the surface areas of the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, and 622a differ depending on the location on the surface of the cushion member 20, 120, 220, 320, 420, 520, and 620. This allows the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, 622a to be formed with a surface area that corresponds to the body part supported by the cushion member 20, 120, 220, 320, 420, 520, 620, and allows compressive deformation according to the body (body weight distribution) being supported. Therefore, the cushion member 20, 120, 220, 320, 420, 520, 620 can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0126] Furthermore, the mattress member 10, 210 according to this embodiment is formed by arranging a plurality of the cushion members 20, 120, 220, 320, 420, 520, and 620 described above. According to the mattress member 10, 210 according to this embodiment, the small elastic bodies 22a, 122a, 222a, 322a, 422a, 522a, and 622a can each independently support the body, and can undergo compressive deformation according to the body weight distribution. Therefore, the mattress member 10, 210 can improve at least one of the ability to turn over in bed and the ability to distribute body pressure.

[0127] (Supplementary Items) (Supplementary Item 1) A method for manufacturing a cushion member made of urethane foam, wherein at least the surface layer of the cushion member is provided with small elastic bodies partitioned by a plurality of continuous linear cuts (slits) formed by groove processing with a contour blade or slit processing with a Thomson blade. This facilitates slit processing and groove processing in at least the surface layer. (Supplementary Item 2) A method for manufacturing a cushion member as described in Supplementary Item 1, wherein the cushion member is made of two or more layers of urethane foam laminated together. This facilitates slit processing and groove processing in multiple layers. (Supplementary Item 3) A method for manufacturing a cushion member as described in Supplementary Item 1 or Supplementary Item 2, wherein the small elastic bodies are connected to adjacent members by connecting parts, the connecting parts being formed so as to extend along the thickness direction of the cushion member, or the connecting parts being formed on the cuts (slits) by providing notches in a Thomson blade. This allows the small elastic bodies to be reliably connected by the connecting parts, thereby imparting firmness to the cushion member. (Additional Item 4) A cushion member, wherein when a pressure probe for hardness measurement according to JIS K6400-2 is placed on the surface of the cushion member and pulled horizontally, the tension is 20.5 N or less. (Additional Item 5) A cushion member, wherein the amount of sinking due to the S-shaped curve of the lower back in a lying position is 20 to 30 mm.

[0128] Furthermore, the disclosure of this specification reveals the following inventions: In the mattress described below, the first region that supports the shoulders is softer than the second region, so resistance to the shoulders when turning over is small, and the mattress is excellent in turning over.

[0129] (Appendix 6) A mattress comprising a first region for supporting the head and shoulders, a second region for supporting the lower back and buttocks, and a third region for supporting the feet, wherein the second region is harder than the first region.

[0130] (Appendix 7) A mattress comprising: a first region supporting the head and shoulders and having a hardness of 60 to 180N; a second region supporting the lower back and buttocks and having a hardness of 70 to 200N; and a third region supporting the feet and having a hardness of 60 to 180N, wherein the second region is harder than the first region.

[0131] In the mattresses described in Supplementary Items 6 and 7, the second region is preferably harder than the third region. In the mattresses described in Supplementary Items 6 and 7, the first region and / or the second region preferably have a slit. In the mattresses described in Supplementary Items 6 and 7, a lower mat (lower layer mat) is preferably provided below the first region, the second region, and the third region.

[0132] Examples of the hardness of the first region and the third region described in Supplementary Items 6 and 7 are independently 60 to 150 N, 70 to 140 N, and 80 to 130 N. Examples of the hardness of the second region (and the lower mat) described in Supplementary Items 6 and 7 are independently 80 to 190 N, 90 to 180 N, 100 to 170 N, and 110 to 160 N.

[0133] 10, 210...Mat member, 20, 120, 220, 320, 420, 520, 620...Cushion member, 22a, 122a, 222a, 322a, 422a, 522a, 622a...Small elastic body, 23, 24, 124, 223, 224, 324, 424...Connecting portion, P, Pc, Pd, Pe, Pf...Intersection, Sa, Sb, Saa, Sba, Sc, Sd, Se1, Se2, Sf...Cut line.

Claims

1. A cushion member formed of an elastic material, small elastic bodies partitioned by a plurality of the cuts formed by intersecting with other cuts, The small elastic bodies are connected to adjacent members by connecting portions, The connecting portion is formed between two adjacent points among the intersections where the cuts intersect, The cushion member is characterized in that the cuts are formed by cutting with a blade.

2. A cushion member formed of an elastic material, The elastic body has small elastic bodies partitioned by continuous cuts having a predetermined linear shape, The small elastic bodies are connected to adjacent members by connecting portions, the cushion member has the slit on a surface side that can be touched by a person, the connecting portion is connected to the cushion member at a rear side end in a thickness direction thereof, The cushion member is characterized in that the cuts are formed by cutting with a blade.

3. A cushion member comprising small elastic bodies formed of an elastic material and partitioned by a plurality of slits formed by intersecting with other slits, or small elastic bodies partitioned by continuous slits of a predetermined linear shape, The linear shape of the cuts is formed so that the surface area of ​​the small elastic bodies varies depending on the location on the surface of the cushion member, and the cushion member in which the small elastic bodies are partitioned is It is formed by arranging multiple The mat member is characterized in that the cuts are formed by cutting with a blade.

4. A cushion member described in any one of claims 1 to 3, characterized in that the planar shape of the small elastic body is a triangle, a square, a hexagon, a circle, or an ellipse.

5. A cushion member formed of an elastic material, The elastic body is provided with small elastic bodies partitioned by a plurality of cuts formed by intersecting with other cuts, or small elastic bodies partitioned by cuts of a continuous predetermined linear shape, The small elastic body has a planar shape of an isosceles triangle, a circle, or an ellipse, The cushion member is characterized in that the cuts are formed by cutting with a blade.