JP2005168964A - Film sandwich type cushion material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a film sandwich type cushion material having a soft and cushioning feeling at initial abutment regardless of the weight of a user or the load of an object, which turns into a rigid cushioning feeling after the user or the object sinks in to a degree, having durability, hardly permanently setting in fatigue, and only requiring relatively reduced manufacturing costs. <P>SOLUTION: Profile-processed surfaces 20 of a plurality of cushion materials 2 made of a profile-processed soft resin foam are opposed to each other, and elastic films 3 are sandwiched and provided therebetween. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a cushioning material that can be used for, for example, a mattress for bedding, a chair or a sofa, and particularly relates to improvement of cushioning properties and durability.

  It is generally known that the weight of the human waist is 44% of the weight and the chest is 33%, and when using a mattress for bedding, the weight increases as the weight increases. And chest subsidence increases. Therefore, when designing a mattress for bedding, it is necessary to set the hardness while fully considering this phenomenon.

  FIG. 12 is a graph showing the weight and the amount of sinking of the mattress for bedding with respect to the weight, and the unprocessed block-shaped cushion material that is not subjected to profile processing of a commonly used urethane foam is indicated by a broken line in FIG. It shows such characteristics. In other words, it is too hard for a lightweight person and sinks rapidly after a certain weight, and the urethane foam raw block cushion material has a very narrow range for setting an appropriate weight.

As measures for solving such problems, laminating soft foamed resins having different hardnesses or profile processing of urethane foam to form a corrugated surface (for example, see Patent Document 1). ). The measurement data of a general profiled cushion material is shown by a one-dot chain line in FIG. 12, and has the characteristic that the increase in weight and the amount of subsidence change to a linear shape that is approximately proportional. Yes.
Here, the relationship between the ideal weight of the mattress for bedding and the sinking is described. As shown by the double line in FIG. 12, even if the user's weight changes, the sinking amount maintains a certain amount of sinking. It remains constant. That is, in the case of a lightweight person, it shows characteristics like the profile processed cushion material in FIG. 12, and in the case of a heavy person, it shows characteristics like the unprocessed block cushion material in FIG. For a heavy person, it can be said that what shows the characteristic that the sinking amount of both the above is connected with a straight line is close to an ideal bedding mattress. In addition, since the weight varies depending on the body part even for the same person, the amount of sinking differs depending on the body part in conventional mattresses for bedding, but for bedding regardless of the weight of the body part. If the amount of the mattress sinking is substantially the same, it can be expected that the sleeping posture is improved.
Japanese Patent No. 3168513

  The present invention is made from such a background, and there is a soft cushion feeling at the time of initial contact regardless of the weight of the user and the load of the object, and after the user or the object sinks to some extent, it is harder. It is intended to realize a new film sand type cushioning material that changes to a cushion feeling, is rich in durability, is less prone to settling, and is relatively inexpensive to manufacture.

  That is, the film sand type cushioning material according to claim 1 is characterized in that profile processing part surfaces of a plurality of cushioning materials made of profiled soft foam resin are opposed to each other, and an elastic film is sandwiched therebetween. Is.

  Furthermore, in the film sand cushion material according to claim 2, in addition to the requirement of claim 1, the initial reaction force at the time of compression is a reaction force mainly due to the elastic film being stretched, and a predetermined force The reaction force after compressive deformation is characterized by the reaction force of the elastic film and the reaction force accompanying the deformation of the plurality of cushion materials.

  Moreover, the film sand type | mold cushioning material of Claim 3 adds to the requirements of the said Claim 1 or 2, and the profile process part surface of the said cushion material facing the convex part of the profile process part surface of one said cushion material This is characterized in that the position is set opposite to the concave portion of the.

  The film sand type cushion material according to claim 4 is characterized in that, in addition to the requirements of claim 1, 2, or 3, the cushion material is two sheets, and one elastic film is sandwiched therebetween. It consists of

  Moreover, the film sand type | mold cushioning material of Claim 5 WHEREIN: In addition to the requirements of the said Claim 1, 2, 3 or 4, the said cushion raw material is a urethane foam, The said elastic film is a urethane film. It consists of features.

  The film sand type cushioning material according to claim 6 is a mattress for bedding or a cushioning material for a seating surface in addition to the requirements of claim 1, 2, 3, 4 or 5. .

The film sand type cushion material of the present invention has the following effects by the above-described means.
That is, according to the film sand type cushioning material of claim 1, it is soft in the initial contact with the object, and after the object sinks into the film sand type cushioning material to some extent, it becomes a hard cushion feeling, and the object is firmly to support. And since it is excellent in the holding | maintenance property of an object, it is suitable also as a cushion material for conveyance of various fruits and electronic parts, etc. which are difficult to convey besides the mattress for bedding and the cushion material of a chair. Further, as a chair, for example, it is suitable as a cushion material for a vehicle seat such as a vehicle because it has a holdability and a feeling of wrapping due to soft depression. In addition, the compression characteristics of flexible foamed resins with the same hardness can be adjusted widely, and various cushioning materials can be produced while reducing production costs without the need for multiple flexible foamed resin molding equipment for each hardness. The development of the use of the cushion material can be expected. Further, the compressive residual strain rate can be kept low, so-called settling does not occur, and it can withstand repeated use over a long period of time.

  Further, according to the film sand type cushioning material according to claim 2, in the initial compression, the reaction force is almost a reaction force of only the elastic film, so that the reaction force after the predetermined compression deformation is a weak reaction force. Because of the reaction force of the elastic film, it is a strong reaction force.

  Further, according to the film sand type cushion material of claim 3, since the concave portion and the convex portion of the profile processing portion surface of the upper and lower cushion materials are set oppositely, mainly in the initial compression stage, In the space that exists between the concave and convex portions facing each other of the cushion material, a weak reaction force acts when the elastic film is stretched by being supported by the concave portions and pushed by the convex portions. And in the compression stage after the middle stage where the elastic film is stretched out and there is no space between the concave part and convex part of the profile processing surface part, this time, the concave and convex part of the cushion material sandwiches the elastic film in between. A strong reaction force due to compression as a whole acts.

  In addition, according to the film sand type cushioning material according to claim 4, since it is a structure in which one elastic film is sandwiched between two cushioning materials, the structure is simple, the manufacturing process is relatively small, and the manufacturing cost is relatively small. This is a configuration suitable for a case where the overall compression amount (sink amount) is not so large.

  According to the film sand type cushioning material of claim 5, when urethane foam is used as the flexible foamed resin and further urethane film is used as the elastic film, the cushioning material is soft and excellent in elasticity, and relatively processed. Easy and durable.

  According to the film sand type cushioning material of claim 6, when the film sand type cushioning material is applied to a mattress for bedding or a cushioning material for sitting, the body is softly wrapped when sleeping or sitting. After the sinking and a predetermined amount of sinking, the user's body is firmly supported while maintaining a certain amount of sinking regardless of the weight of the user and the parts of the head, waist and legs. In particular, regardless of the parts of the body, such as the head, waist, and legs, a constant amount of depression is maintained, so that the sleeping posture is improved, and a good sleep is promoted and health is promoted.

  The best mode of the present invention is specifically described in the following examples.

The present invention will be described below based on the illustrated embodiments.
FIG. 1 shows an embodiment in which the film sand type cushion material of the present invention is applied to a mattress for bedding. The film sand type cushion material 1 of the present invention formed in a rectangular mat shape is made of cotton, chemical fiber, or the like. The cover C is covered.

  The film sand type cushioning material 1 will be described in detail. In this example, the profile processing part surface 20 of the cushioning material 2 made of two soft foamed resins subjected to profile processing is opposed to each other, and an elastic film 3 that can be stretched between them. It consists of.

  The cushion material 2 is specifically formed of urethane foam, and for example, a material having a hardness of about 159.6 ± 19.6 N (JIS K6400) is used. The cushion material 2 has a sheet shape, and as an example, a wavy profile processed portion surface 20 with small protrusions is formed on one surface. As shown in FIG. 3, one or both of the two cushion materials 2 are formed with profile processed portion surfaces 20 on both the upper and lower surfaces for the purpose of eliminating the finger pressure effect on the user's body and the effect of eliminating stuffiness. May be. The cushion material 2 can be made of various types of flexible foamed resins in accordance with other application purposes in addition to using urethane foam.

On the other hand, as the elastic film 3, for example, a urethane film can be used. For example, a urethane film having a hardness of 90 (JIS A) is used.
In addition to the urethane film, various elastic films made of, for example, rubber can be applied according to other application purposes.

  The apex of each convex part 21 of the profile processed part surface 20 of the cushion material 2 and the elastic film 3 are bonded and fixed with an adhesive. In addition, as FIG. 2 etc. show, the convex part 21 of the profile process part surface 20 of the upper and lower cushion materials 2 is set oppositely to the recessed part 22 of the profile process part surface 20 of the cushion material 2 which opposes. Is preferred. Moreover, it is preferable that the profile process surface parts 20 of the upper and lower cushion materials have the same profile (for example, a waveform shape). This can be achieved, for example, by using a pair of profiled soft foam resins as the upper and lower cushion materials 2 as they are, or using a soft foam resin profiled with the same mold.

  The film sand type cushioning material 1 of the present invention is mainly subjected to a reaction force due to expansion of the elastic film 3 in the initial compression, and after a predetermined compression deformation, the deformation of the cushion material 2 and the reaction force against the elastic film 3 act. It is preferable to do. In this case, it is possible to set the apparent hardness of the cushion material 2 on the profile processed part surface 20 side to be higher than the apparent hardness in the thickness direction of the elastic film 3. The hardness of the two is different in the measurement method and depends on the stretched state of the elastic film 3 and the like, but a simple comparison cannot be made, but the relative hardness relationship is preferably as described above.

When the film sand cushion material 1 of the present invention is used as described above, the following effects are obtained.
When the film sand cushion material 1 (bedding mattress) is laid down, the film sand cushion material 1 is initially submerged and is soft and thus feels like it wraps around the body (FIG. 2 (a) ( b)). After a predetermined amount of soft subsidence, the reaction force of the film sand cushion material 1 becomes stronger after the concave portions 22 and the convex portions 21 of the profile processing portion surface 20 of the upper and lower cushion materials 2 are engaged with each other. (See FIGS. 2 (b) and 2 (c)), regardless of the weight of the user, the user's body is firmly supported while maintaining a constant sinking amount (see FIG. 2 (c)). In addition, it is difficult to stick even after long-term repeated use.
The film sand cushion material 1 of the present invention is used for a mattress for bedding as described above, as a cushion material for seat cushions and chairs, as a cushion material for seat surfaces and backrests of vehicle seats, and as a package itself. Can be applied as a package having a firm cushioning action while softly wrapped.

(A) Comparison of difference in sinking amount of each cushion material due to load FIG. 4 shows a graph comparing the relationship between the sinking amount of the film sand cushion material 1 of the present invention and other cushion materials with respect to the load.
In FIG. 4, what is indicated by a solid line is an example of the film sand cushion material 1 of the present invention, and has the configuration of the film sand cushion material 1 shown in FIGS. Specifically, as this cushion material 2, urethane foam ERG-M (hardness: 156.9 ± 19.6 N, JIS K6400) manufactured by INOAC CORPORATION is used.
The elastic film 3 is a urethane film having a thickness of 100 μm and a hardness of 90 (JIS A).
What is indicated by a broken line is Comparative Example 1 and does not sandwich the elastic film 3 between the cushion materials 2 and does not have the profile processed portion surface 20 and is a cushion material using urethane foam (unformed). ERG-M (hardness: 156.9 ± 19.6 N, JIS K6400) manufactured by Inoac Corporation of the above example is used as the urethane foam.
Also, the one shown by the alternate long and short dash line is Comparative Example 2, in which the convex portions 21 of the profile processed portion surface 20 are directly brought into contact with each other without sandwiching the elastic film 3 between the cushion materials 2 (elastic film removal profile processing). As the cushion material 2, urethane foam ERG-M (hardness: 156.9 ± 19.6 N, JIS K6400) manufactured by Inoac Corporation of the above example is used.
In FIG. 4, what is indicated by a double line is an ideal line of the film sand type cushioning material 1, and the amount of sinking of the cushioning material is constant like this ideal line even if the user's weight changes. Ideally.

From FIG. 4, the urethane foam cushion material in which nothing is processed in Comparative Example 1 (broken line) has a low sinking amount and feels hard when it is a lightweight person or a normal weight person. Sink into. As a result, the appropriate weight range is very narrow.
Moreover, the elastic film removal profile processing cushion material of the comparative example 2 (a dashed-dotted line) increases in the state where the amount of sinking is substantially proportional to the increase in weight. Compared to the urethane foam cushioning material that is not processed with any broken line, a cushioning effect can be obtained even with a lightweight one. It is necessary to purchase mattresses for bedding using urethane foam.
And the cushioning material using the film sand type cushioning material 1 of the embodiment of the present invention initially has a relatively rapid sinking amount corresponding to the increase in weight. The amount of sinking is reduced to near the weight of the body, and it shows the characteristics of the flat sinking amount that is closest to the ideal line of the double line compared to the other cushion materials mentioned above, regardless of the relative weight difference, The amount of sinking of the cushion material remains within a substantially constant range.

(B) Comparison of difference in reaction force of each cushion material with respect to compression amount Next, a comparative experimental example comparing the reaction force with respect to the compression amount between the film sand cushion material 1 of the present invention and another cushion material is shown in FIG. Show.
First, as an example of the film sand type cushion material 1 of the present invention (shown by a solid line in the figure), the film sand type cushion material 1 having the configuration shown in FIG. 1 and FIG. Urethane foam ERG-M (hardness: 156.9 ± 19.6N, JIS K6400) manufactured by Inoac Corporation is used. The elastic film 3 is a urethane film having a thickness of 100 μm and a hardness of 90 (JIS A). And the profile process part surface 20 of the cushion raw material 2 which consists of a soft foam resin by which two profiles were processed is made to oppose, and the elastic film 3 is pinched | interposed between these. In this state, the film sand cushion material 1 of the example has a cylindrical shape with a diameter of 150 mm and a height of 60 mm.
Further, Comparative Example 1 (indicated by a broken line in FIG. 5) is a urethane foam which is not integrally formed with the elastic film 3 between the cushion materials 2 and does not have the profile processing part surface 20 and is integrally formed in a cylindrical shape. Specifically, urethane foam ERG-M (hardness: 156.9 ± 19.6N, JIS K6400) manufactured by Inoac Corporation is used.
Further, Comparative Example 2 (indicated by a two-dot chain line in the figure) is a comparative example in which an aluminum plate having a thickness of 0.2 mm is sandwiched in place of the elastic film 3 in the above-described example. It can be estimated what compression correspondence is shown when a hard object is used.
The test conditions were a compression rate of 100 mm / min, a circular aluminum plate having a diameter of 150 mm as a compression jig, and a room temperature of 22 degrees.
In FIG. 5, the area indicated by arrow A indicates the initial stage of compression, the area indicated by arrow B indicates the middle stage of compression, and the area indicated by arrow C indicates the latter stage of compression.

Regarding the experimental results, what can be said from FIG. 5 is that the film sand type cushioning material 1 of the example has a very weak reaction force in the early stage of compression in the A region, and then the reaction force increases rapidly in the middle of the compression in the B region. The reaction force is about the same as that of the general urethane foam of Comparative Example 1 at a compression amount of about 20 mm in the early stage of compression in the later stage of the region. Thereafter, the general urethane foam of Comparative Example 1 is pulled out and the reaction force depends on the compression amount. Will strengthen.
Moreover, the cushion material (raw block-shaped cushion material) which consists of the general block-shaped urethane foam of the comparative example 1 shown with a broken line increases reaction force rapidly from the compression initial stage of A area | region, and increases the amount of compression after that. Along with this, the reaction force increases very slowly in a state of almost leveling off.
Further, the aluminum plate sand type cushion material of Comparative Example 2 (indicated by a two-dot chain line) shows substantially the same reaction force as that of the example of the present invention at the initial stage of compression, and thereafter, the reaction force does not increase suddenly and is almost equal. The reaction force increases with a curve close to a proportional straight line.

(C) Comparison of difference in compression residual strain of each cushion material Table 1 shows the results of compression residual strain test (endurance test) between the film sand cushion material 1 of the present invention and another cushion material.
The example uses the same conditions as the film sand cushion material 1 shown in the comparative experimental example for comparing the reaction force against the compression amount in FIG. 5, and the comparative example shows the reaction against the compression amount in FIG. Same as the cushion material (unprocessed block-shaped cushion material) using urethane foam integrally formed in a cylindrical shape without having the profile processing part surface 20 of the comparative example 1 shown in the comparative experimental example for comparing the force Those with conditions are used. Specifically, the film sand type cushion material 1 of the example is ERG-M (hardness: 159.6 ± 19.6 N, JIS K6400) manufactured by INOAC CORPORATION as the cushion material 2, and the thickness is 100 μm as the elastic film 3. A urethane film having a hardness of 90 (JIS A) was used, and the hardness of about 94.3 N (JIS K6400) was measured before the experiment for the film sand cushion material 1 as a whole. On the other hand, the cushion material of the comparative example (raw block-shaped cushion material) was TNW (hardness: 83.3 ± 19.6N, JIS K6400), a urethane foam manufactured by Bridgestone Corporation. It was 85.4N (JIS K6400).
In addition, the specific measurement of the compressive residual strain of each cushion material is as follows. First, the thickness of the central portion of the test piece (each cushion material) is set to 0.1 mm with a measuring instrument in a state where the flexible foamed resin (foam) is not deformed. Then, the test piece is compressed and fixed to 75% of the thickness of the test piece using two compression plates. Then, it is placed in a thermostatic chamber at a temperature of 70 ± 1 ° C. while being compressed within at least 15 minutes and heated for 22 hours. Thereafter, the test apparatus is taken out of the thermostatic chamber, and the test piece is taken out from the compression plate within one minute and placed on a material having low thermal conductivity such as wood, and the test piece is placed at a temperature of 23 ± 2 ° C. and relative humidity (relative humidity ( After being allowed to stand for 30 minutes under the condition of 50 ± 5)% and recovered, the thickness of the same part as before is measured to a unit of 0.1 mm.

  From Table 1, the hardness of the film sand type cushioning material 1 of the example before the experiment and the cushioning material of the comparative example are 94.3N and 85.4N (JIS K6400), respectively, which are almost equivalent. The compressive residual strain obtained after the experiment was 4.2% for the example and 8.3% for the comparative example. Accordingly, it can be determined that the embodiment has a smaller distortion rate and is less likely to stick. Incidentally, the compression residual strain rate of what is called an excellent mat in the industry is about 5.0%, and the film sand cushion material 1 of the embodiment is superior to that. As described above, it is judged that the reason why the example shows a better value for the compressive residual strain ratio than the comparative example is that the compressive residual strain of the profiled cushion material 2 and the elastic film 3 is small. To do.

Although the above-mentioned film sand cushion material 1 of the present invention is a basic embodiment, various other modifications can be made.
For example, as shown in FIG. 6, the unevenness 3 a is provided by vacuum formation or the like on the elastic film 3 in accordance with the unevenness of the profile processing portion surface 20 of the cushion material 2 so as to reduce the deviation between the cushion material 2 and the elastic film 3. It may be. At this time, it is possible to adjust the distance between the opposing cushion materials 2 by the depth of the unevenness 3a of the elastic film 3, and by changing this gap, the above-described A region (initial compression stage) in FIG. It is possible to adjust the reaction force in the B region (mid-compression period).

  Further, it is possible to perforate a plurality of holes in the elastic film 3 to positively change the sinking amount. Basically, when a hole is drilled in the elastic film 3, the apparent hardness of the portion becomes soft. FIG. 7 shows an embodiment in which a plurality of holes 3b are formed in the vicinity of the leg support with a small load.

Moreover, when using as a cushion material for the seat surface of a chair etc., as shown in FIG. 8, you may make it vary the thickness of the cushion material 2 which opposes. By comprising in this way, it becomes possible to obtain the cushion material which can obtain a different cushion feeling by the front and back about the cushion material for the seat surface of a chair. In the case of such a configuration, the cushion material can be used as a so-called reversible according to the user's preference. Incidentally, as shown in FIG. 8A, when the upper cushion material 2 is arranged so as to be thin, it feels soft and feels uncomfortable. On the other hand, when the upper cushion material 2 is disposed so as to be thick as shown in FIG. 8 (b), it feels relatively hard while feeling very rare. In addition, in obtaining the cushion material which can obtain a different cushion feeling by the front and back, it is also possible by changing the hardness of the cushion material which opposes, and it is also possible to implement by modifying in that way.
Of course, the modified configuration as described above can be applied not only to the cushioning material for the seat surface of the chair but also to a mattress for bedding and other cushioning materials that can be used upside down.

  The film sand cushion material 1 of the present invention can be implemented in two or more stages such as three stages or four stages as shown in FIG. Incidentally, the more the number of steps is, the larger the sinking amount of the film sand cushion material 1 is.

When the film sand cushion material 1 is used as a mattress for the bed B, the elastic film 3 may be stretched around the surrounding bed frame using staples 4 or the like as shown in FIG.
In the case of such a configuration, the film sand cushion material 1 can obtain a stronger reaction force after a predetermined amount of sinking.

  Further, the shape of the profile processed portion surface 20 is not limited to the wave shape of the small protrusions, and various shapes can be applied. For example, as shown in FIG. Shape), or a combination of a radial shape and a wavy shape of small protrusions as shown in FIG. 11B.

It is the exploded perspective view which shows Example 1 which applied the film sand type cushion material of this invention to the mattress for bedding, and the vertical side view which expands and shows a part. It is a vertical side view which shows an action aspect same as the above. It is a vertical side view which shows the other Example in Example 1 which formed the profile process part surface in the upper and lower surfaces of the upper cushion material. It is a graph which compares the difference in the sinking amount of each cushion material by a load. It is a graph which compares the difference of the reaction force of each cushion material with respect to compression amount. It is a disassembled perspective view which expands and shows a part of film sand type cushion material of Example 2 which provided the unevenness | corrugation in the elastic film according to the unevenness | corrugation of the profile process part surface of a cushion raw material. It is a top view which shows the film sand type | mold cushioning material of Example 3 which makes a hole in an elastic film and changes the amount of sinking actively. It is a vertical side view which shows Example 4 which varied the thickness of the opposing cushioning material. It is a vertical side view which shows Example 5 which comprises a cushion raw material in three steps. It is a vertical side view which shows Example 6 which fixed the peripheral edge part of the elastic film to the bed frame. It is a perspective view of Example 7 which shows two types which comprised the shape of the profile process part surface differently. It is a graph which compares the difference of the sinking amount by the load of each conventional cushion material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Film sand type cushion material 2 Cushion material 20 Profile processing part surface 21 Convex part 22 Concave part 3 Elastic film 3a Concavity and convexity 3b Hole 4 Staple B Bed C Cover

Claims (6)

  A film sand type cushioning material characterized in that a profile processing part surface of a plurality of cushion materials made of profiled soft foam resin is opposed to each other and an elastic film is sandwiched therebetween.   The reaction force at the time of initial compression is a reaction force mainly due to the elastic film being stretched, and the reaction force after a predetermined compression deformation is accompanied by the reaction force of the elastic film and the deformation of the plurality of cushion materials. 2. The film sand type cushioning material according to claim 1, which is based on a reaction force.   The film sand mold according to claim 1 or 2, wherein the convex portion of the profile processing portion surface of one of the cushion materials is positioned oppositely to the concave portion of the profile processing portion surface of the opposing cushion material. Cushion material.   The film sand type cushion material according to claim 1, 2 or 3, wherein the cushion material is two sheets, and one elastic film is sandwiched between the two.   The film sand cushion material according to claim 1, wherein the cushion material is urethane foam, and the elastic film is a urethane film.   6. The film sand type cushion material according to claim 1, which is a mattress for bedding or a cushion material for a seating surface.

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