JP2021171487A - Cushioning material, laminated cushioning material, and method of manufacturing cushioning material - Google Patents

Abstract

To provide a cushioning material and a laminated cushioning material, which are structurally simplified while having an uneven shape formed on each of two surfaces, and a method of manufacturing the cushioning material, which is suitable for obtaining the cushioning material.SOLUTION: A cushioning material 1 has two surfaces F1 and F2. The cushioning material 1 is a single member that is formed of a resin foam. An uneven shape on the side of one surface is formed on either of the two surfaces F1 and F2. An uneven shape on the side of the other surface is formed on the other one of the two surfaces F1 and F2. An array pitch P2 of the uneven shape on the side of the other surface is longer than an array pitch P1 of the uneven shape on the side of one surface.SELECTED DRAWING: Figure 2

Description

The present invention relates to a cushioning material, a laminated cushioning material, and a method for manufacturing the cushioning material.

In the conventional cushion material, there is a cushion material having different uneven shapes on each of the two surfaces, the front surface and the back surface (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2019-54937

However, the conventional cushioning material is formed by sticking two sheet bodies together with an adhesive. Therefore, the conventional cushion material has room for improvement in terms of simplification of the structure.

An object of the present invention is to provide a cushioning material and a laminated cushioning material having a concave-convex shape on each of the two surfaces and having a simplified structure, and is suitable for obtaining the cushioning material. It is to provide a method of manufacturing a cushion material.

The cushioning material according to the present invention is a cushioning material having two surfaces, the cushioning material is a single member formed of a foamed resin, and one of the two surfaces is covered with one. It has a concavo-convex shape on the direction side, and has a concavo-convex shape on the other side on one of the two surfaces, and the arrangement pitch of the concavo-convex shape on the other side is the uneven shape on the one side. Longer than the array pitch of. According to the cushion material according to the present invention, the structure is simplified while having an uneven shape on each of the two surfaces.

Further, in the cushion material according to the present invention, the one-sided concavo-convex shape is composed of a plurality of one-sided concavo-convex portions, and the plurality of one-sided concavo-convex portions are in a predetermined direction and in the predetermined direction in a plan view. The concavo-convex shape on the other side is composed of a plurality of concavo-convex portions on the other surface side, and the plurality of concavo-convex portions on the other surface side are arranged in each direction with respect to the intersecting directions. It is preferable that the array is arranged only in one of the predetermined direction and the intersection direction, and extends in the other direction of the predetermined direction and the intersection direction. In this case, one surface of the cushion material can be used as a surface having excellent pressure dispersibility, and the other surface of the cushion material can be used as a surface having excellent air permeability.

Further, in the cushion material according to the present invention, the one-sided convex portion includes a one-sided convex portion and a one-sided concave portion, and the one-sided convex portion has a conical shape and is said to be one-sided. It is preferable that the concave portion has an inverted cone shape, the concavo-convex portion on the other surface side includes a convex portion on the other surface side and a concave portion on the other surface side, and the concavo-convex shape on the other surface side has a planar wavy shape. In this case, one surface of the cushion material can be used as a surface having better pressure dispersibility, and the other surface of the cushion material can be used as a surface having better air permeability.

The laminated cushion material according to the present invention includes two cushioning materials, and at least one of the two cushioning materials is the cushioning material described above, and at least one of the other surfaces of the two cushioning materials. And the other cushion material are laminated and arranged so that the other cushion material faces each other. According to the laminated cushion material according to the present invention, the structure is simplified while having an uneven shape on each of the two surfaces.

In the laminated cushion material according to the present invention, the two cushioning materials are the cushioning materials described above, respectively, and the other surface of one cushioning material and the other surface of the other cushioning material face each other. It is preferable that the one cushion material and the other cushion material are laminated so as to be aligned. In this case, the structure is further simplified while having an uneven shape on each of the two surfaces.

The method for producing a cushion material according to the present invention is a method for producing a cushion material for obtaining the above-mentioned cushion material, which is a one-side surface layer portion and the other surface side surface layer of a single base material formed of a foamed resin. The first processing step of forming the other surface of the cushion material by performing two-dimensional processing on each of the portions, and the waste material of the base material generated in the first processing step are used as the base material. It includes a removing step of removing from the cushion material and a second processing step of forming the one surface of the cushioning material by performing profile processing on the base material after the removing step. The method for producing a cushion material according to the present invention is suitable for obtaining the cushion material.

According to the present invention, it is possible to provide a cushioning material and a laminated cushioning material having a concave-convex shape on each of the two surfaces and having a simplified structure, and it is suitable for obtaining the cushioning material. A method for manufacturing a cushion material can be provided.

It is a perspective view which shows typically the cushion material which concerns on one Embodiment of this invention. It is a side view of the cushion material of FIG. It is a front view of the cushion material of FIG. It is a top view, a front view and a right side view which show schematicly the laminated cushion material which concerns on one Embodiment of this invention. It is an enlarged view which shows the region A of FIG. It is a top view, a front view and a right side view which show schematicly the laminated cushion material which concerns on other embodiment of this invention. In the first processing step of the method for producing a cushion material according to an embodiment of the present invention, the two-dimensionally processed base material is schematically shown in a state where the waste material generated by the two-dimensional processing remains. It is a side view. FIG. 5 is a cross-sectional view schematically showing an example of two-dimensional machining performed in the first machining step of FIG. 7 from the front. FIG. 5 is a cross-sectional view schematically showing a two-dimensional machining performed in the first machining step of FIG. 7 from the side surface. In the removal step after the first processing step of FIG. 7, after removing the waste material from the two-dimensionally processed base material of FIG. 7, the profile-processed group is further in the second processing step after the removal step. It is a side view which shows the material roughly. FIG. 5 is a cross-sectional view taken along the line XX of FIG. 10 showing an example of profile processing performed in the second processing step of FIG. 10 schematically from the front. FIG. 11 is a cross-sectional view taken along the line XX of FIG. 11 showing an example of profile processing schematically in the second processing step of FIG. 10 from the side surface. It is a side view which shows typically the process of forming the laminated cushion material which concerns on this Embodiment using the secondary processed base material of FIG. It is a top view which shows an example of the surface side uneven shape of the cushion material which concerns on still another Embodiment of this invention by enlarging a part of the surface side uneven shape. It is a perspective view which shows a part of FIG. 14 further enlarged.

Hereinafter, a method for manufacturing the cushion material, the laminated cushion material, and the cushion material according to the embodiment of the present invention will be described with reference to the drawings.

[Cushion material]
In FIG. 1, reference numeral 1 is a cushioning material according to an embodiment of the present invention. In the present embodiment, the cushion material 1 is a rectangular sheet. In the present embodiment, the length L of the cushion material 1 is longer than the width W of the cushion material 1. Further, the thickness T of the cushion material 1 is thinner than the width W of the cushion material 1. In this embodiment, the cushion material 1 is a mattress. In FIG. 1, the reference numeral DL is in the length direction (length direction). Further, in FIG. 1, the reference numeral DW is in the width direction. Further, in FIG. 1, the reference numeral DT is in the thickness direction.

The cushion material 1 has two surfaces. In the present embodiment, the cushion material 1 has two surfaces, a front surface F1 and a back surface F2. Further, the cushion material 1 is a single member formed of a foamed resin. The foamed resin is preferably a soft foamed resin. Specific examples include flexible polyurethane foam. The cushion material 1 has a concavo-convex shape on one side of either the front surface F1 or the back surface F2. In the present embodiment, the one-sided uneven shape is a surface-side uneven shape provided on the side of the surface F1. In FIG. 1, a part of the concave-convex shape on the surface side is omitted by the alternate long and short dash line. Further, the cushion material 1 has a concavo-convex shape on the other side on the other surface of either the front surface F1 or the back surface F2. In the present embodiment, the concavo-convex shape on the other side is the concavo-convex shape on the back surface side provided on the back surface F2 side. The arrangement pitch P2 of the concavo-convex shape on the other side is longer than the arrangement pitch P1 of the concavo-convex shape on the one side. In the present embodiment, the arrangement pitch P1 having the uneven shape on one side is the arrangement pitch having the uneven shape on the surface side. Further, in the present embodiment, the arrangement pitch P2 of the concavo-convex shape on the other side is the arrangement pitch of the concavo-convex shape on the back surface side.

In the present embodiment, the surface-side uneven shape is composed of a plurality of surface-side uneven portions 2. In the present embodiment, the surface-side uneven portion 2 is a one-sided uneven portion. The arrangement pitch P1 of the surface-side uneven shape is, for example, an arbitrary pitch P1p between an arbitrary surface-side convex portion (one-sided convex portion) 2a and the surface-side convex portion 2a closest to the surface-side convex portion 2a. The pitch P1n between the surface side concave portion (one side concave portion) 2b and the surface side concave portion 2b closest to the surface side concave portion 2b, or any surface side convex portion 2a or the surface side concave portion 2b and the surface side convex portion. The pitch P1pn between the 2a or the surface side concave portion 2b closest to the surface side concave portion 2b or the surface side convex portion 2a can be set. In the present embodiment, the plurality of surface-side uneven portions 2 are arranged in the respective directions of a predetermined direction and an intersecting direction intersecting with the predetermined direction in a plan view. In the present embodiment, the predetermined direction is a direction parallel to the length direction DL. Referring to FIG. 2, the arrangement pitch P1 of the surface-side concavo-convex shape is, for example, the pitch P1p between the surface-side convex portion 2a and the surface-side convex portion 2a, and the surface-side concave portion 2b and the surface side in the length direction DL. It can be the pitch P1n between the concave portion 2b or the pitch P1pn between the surface side convex portion 2a and the surface side concave portion 2b. Further, the crossing direction is a direction in which the crossing direction intersects with the length direction DL in a plan view. In the present embodiment, the crossing direction is a direction orthogonal to the length direction DL, that is, a direction parallel to the width direction DW in a plan view. With reference to FIG. 3, the array pitch P1 having the uneven shape on the surface side has, for example, the pitch P1p between the convex portion 2a on the surface side and the convex portion 2a on the surface side, and the concave portion 2b on the surface side and the concave portion on the surface side in the width direction DW. It may be the pitch P1n between 2b or the pitch P1pn between the surface side convex portion 2a and the surface side concave portion 2b.

Further, in the present embodiment, the back surface side uneven shape is composed of a plurality of back surface side uneven portions 3. In the present embodiment, the back surface side uneven portion 3 is the other surface side uneven portion 3. Referring to FIG. 2, the arrangement pitch P2 of the back surface side uneven shape is, for example, an arbitrary back surface side convex portion (the other surface side convex portion) 3a and the back surface side convex portion 3a closest to the back surface side convex portion 3a. Pitch P2p between, the pitch P2n between any back surface side recess (recess on the other side) 3b and the back surface side recess 3b closest to the back surface side recess 3b, or any back surface side convex portion 3a or back surface side recess The pitch P2pn can be set between 3b and the back surface side concave portion 3b or the back surface side convex portion 3a closest to the back surface side convex portion 3a or the back surface side concave portion 3b. In the present embodiment, the plurality of uneven portions 3 on the back surface side are arranged only in one of the predetermined direction and the intersecting direction in a plan view. In the present embodiment, the predetermined direction is a direction parallel to the length direction DL. Referring to FIG. 2, the arrangement pitch P2 having the concave-convex shape on the back surface side is, for example, the pitch P2p between the convex portion 3a on the back surface side and the convex portion 3a on the back surface side, and the concave portion 3b on the back surface side and the back surface side in the length direction DL. It can be the pitch P2n between the concave portion 3b or the pitch P2pn between the back surface side convex portion 3a and the back surface side concave portion 3b. Further, the plurality of back surface side uneven portions 3 extend in any one of the predetermined direction and the intersecting direction. In this case, a part of the back surface side uneven portion 3 can function as a groove portion extending in any one of the predetermined direction and the intersecting direction. In the present embodiment, the crossing direction is a direction parallel to the width direction DW. Referring to FIG. 3, the back surface side uneven portion 3 extends in the width direction DW. In the present embodiment, the back surface side convex portion 3a and the back surface side concave portion 3b extend in the width direction DW, respectively. In this case, the back surface side recess 3b can function as a groove extending in the width direction DW. In the present embodiment, the back surface side uneven portion 3 is described as being arranged in the same predetermined direction as the front surface side uneven portion 2 (direction parallel to the width direction DW), but the back surface side uneven portion 3 is the front surface side uneven portion 3. It can be arranged in a direction different from that of the side uneven portion 2. Further, in FIG. 3, the contour line of the surface side convex portion 3a indicates the apex of the surface side convex portion 3a. Further, in FIG. 3, the contour line of the back surface side recess 3b indicates the groove bottom of the back surface side recess 3b. That is, the height difference of the back surface side uneven portion 3 is shown between the contour line of the front surface side convex portion 3a and the contour line of the back surface side concave portion 3b shown in FIG.

According to the present invention, the arrangement pitch P2 of the concavo-convex shape on the back surface side is longer than the arrangement pitch P1 of the concavo-convex shape on the front surface side. That is, P2> P1. When the arrangement pitch P1 of the front surface side uneven shape is different, the arrangement pitch P2 of the back surface side uneven shape is preferably longer than the largest arrangement pitch P1 of the front surface side uneven shape arrangement pitch P1. When the arrangement pitch P2 of the back surface side uneven shape is different, it is preferable that the smallest arrangement pitch P2 of the back surface side uneven shape arrangement pitch P2 is longer than the arrangement pitch P1 of the front surface side uneven shape. That is, when the arrangement pitch P1 of the front surface side uneven shape is different and the arrangement pitch P2 of the back surface side uneven shape is different, the smallest arrangement pitch P2 of the back surface side uneven shape arrangement pitch P2 is the arrangement pitch of the front surface side uneven shape. Of P1, it is preferable to make it longer than the largest arrangement pitch P1.

As shown in FIG. 2, in the present embodiment, the arrangement pitch P2 of the back surface side uneven shape is longer than the arrangement pitch P1 of the front surface side uneven shape arranged in the direction parallel to the length direction DL. Further, in the present embodiment, the arrangement pitch P2 of the uneven shape on the back surface side is longer than the arrangement pitch P1 of the uneven shape on the front surface side arranged in the width direction DW.

The cushion material 1 is a single member formed of a foamed resin. The cushion material 1 is formed by, for example, using a sheet-shaped flexible polyurethane foam as a single base material and machining the base material. As for the cushion material 1, the cushion material 1 is provided with an uneven shape on each of the front surface F1 and the back surface F2 of the cushion material 1 without sticking two sheet materials together. Therefore, according to the cushion material 1, the structure of the cushion material 1 is simplified while each of the front surface F1 and the back surface F2 has an uneven shape.

Further, the cushion material 1 does not generate tension due to the adhesion of the two sheet materials. Therefore, according to the cushion material 1, the movement such as turning over during sleep does not cause a shift or pull between the two seat materials as in the conventional cushion material, for example. Therefore, according to the cushion material 1, the pressure distribution performance (the performance of dispersing the pressure applied to the surface F1 of the cushion material 1) can be exhibited without causing unnecessary stress inside the cushion material 1.

Further, in the cushion material 1, the one-sided concavo-convex shape is composed of a plurality of one-sided concavo-convex portions (2), and the plurality of one-sided concavo-convex portions (2) are in a predetermined direction in a plan view. It is preferable that they are arranged in each direction with the intersecting direction intersecting with respect to a predetermined direction. In this case, the one surface of the cushion material 1 can be used as a surface having excellent pressure dispersibility. Further, the concavo-convex shape on the other side is composed of a plurality of concavo-convex portions (3) on the other side, and the plurality of concavo-convex portions (3) on the other surface side can be any of the predetermined direction and the intersecting direction in a plan view. It is preferable that the cells are arranged in only one direction and extend in one of the predetermined direction and the intersecting direction. In this case, the other surface of the cushion material 1 can be used as a surface having excellent breathability. Further, in this case, the comfort during the rolling motion during sleep is also improved.

Referring to FIG. 2, in the present embodiment, the surface-side uneven shape is composed of a plurality of surface-side uneven portions 2. The plurality of surface-side uneven portions 2 are arranged in each of the length direction DL and the width direction DW in a plan view. In this case, the surface F1 of the cushion material 1 can be used as a surface having excellent pressure dispersibility. Further, referring to FIG. 2, in the present embodiment, the back surface side uneven shape is composed of a plurality of back surface side uneven portions 3. The plurality of uneven portions 3 on the back surface side are arranged only in the length direction in a plan view. Further, referring to FIG. 3, the back surface side uneven portion 3 extends in the width direction DW. In the present embodiment, the back surface F2 of the cushion material 1 is formed with a plurality of back surface side recesses 3b extending in the width direction DW. In this case, the back surface F2 of the cushion material 1 can be used as a surface having excellent breathability. The plurality of surface-side uneven portions 2 can be arranged only in the width direction DW instead of the length direction DL. Further, the plurality of surface-side uneven portions 2 can be arranged in a predetermined direction different from the length direction DL and in a direction different from the predetermined direction in a plan view.

[Laminated cushion material]
According to the present invention, the laminated cushion material 10 can be formed by using the cushion material 1. The laminated cushion material 10 includes two cushion materials. In the laminated cushion material 10, at least one of the two cushion materials is the cushion material 1. In the laminated cushion material 10, the cushion material 1 and the other cushion material are laminated so that the other surface (back surface) of the cushion material 1 and the other cushion material face each other.

FIG. 4 is a plan view, a front view, and a right side view schematically showing the laminated cushion material 10 according to the embodiment of the present invention. In FIG. 4, substantially the same parts as the configurations of FIGS. 1 to 3 use the same reference numerals.

With reference to the plan view of FIG. 4, the laminated cushion material 10 is formed of three laminated cushion materials 10A. For the three laminated cushion materials 10A, for example, one laminated cushion material 10 is cut out from the laminated cushion material sheet by vertical processing using a vertical cutter, and the three laminated cushion materials 10A are further cut into three laminated cushion materials 10A.

Referring to the front view of FIG. 4, the laminated cushion material 10A includes two cushion materials 1A. The two cushion materials 1A are cushion materials 1, respectively. In the present embodiment, one cushion material 1A and the back surface (the other surface) F2 of one cushion material 1A and the back surface (the other surface) F2 of the other cushion material 1A face each other. The other cushion material 1A is laminated and arranged. As a result, the two surfaces of the laminated cushion material 10A are each formed by the surface F1 of the cushion material 1A. In the laminated cushion material 10A of FIG. 4, the two cushion materials 1A can be formed of different materials. Further, the back surface F2 of the two cushion materials 1A can have different shapes. Further, the surfaces F1 of the two cushioning materials 1A can also have different shapes. In FIG. 4, the uneven shape of the surface F1 of the laminated cushion material 10A is omitted.

Referring to the side view of FIG. 4, in the present embodiment, the laminated cushion material 10A fits the back surface side uneven shape of one cushion material 1A and the back surface side uneven shape of the other cushion material 1A. There is. As a result, in the laminated cushion material 10A, the two cushion materials 1A can be laminated and arranged without laminating the two cushion materials 1A. Therefore, in this case, the structure is further simplified while having a concave-convex shape on each of the two surfaces, the front surface F1 and the back surface F2.

Further, as described above, the laminated cushion material 10A can be formed by fitting the back surface side uneven shapes of the two cushion materials 1A. Therefore, at the time of manufacturing the laminated cushion material 10A, it is possible to reduce the man-hours for bonding the two cushion materials 1A using an adhesive or the like.

Further, in the present embodiment, the two cushion materials 1A are not bonded by an adhesive or the like unlike the conventional cushion materials. Therefore, the laminated cushion material 10A does not generate tension due to the adhesion of the two cushion materials 1A. Therefore, for example, even when the two cushioning materials 1A are displaced or pulled due to the rolling motion during sleep, the pressure distribution performance (the surface of the laminated cushioning material 10A) is allowed by allowing both of them. (Performance to disperse the pressure applied to) can be exhibited.

The conventional laminated cushion material is formed by laminating two sheet materials (cushion materials). Therefore, the conventional laminated cushion material has a desired effect by, for example, appropriately changing the characteristics of the material, the uneven shape on one side of one cushion material, and the uneven shape on one side of the other cushion material. Is being demonstrated. For example, if the material of the cushion material is changed to an appropriate material, for example, the surface-side uneven shape of one cushion material and the surface-side uneven shape of the other cushion material are changed to an appropriate uneven shape, for example, pressure. The dispersion performance can be improved, and for example, the sleeping comfort can be improved.

On the other hand, the laminated cushion material 10A according to the present embodiment is formed by superimposing two cushion materials 1A. Therefore, in the laminated cushion material 10A, in addition to the characteristics of the material, the uneven shape on the front surface side of one cushion material 1A, and the uneven shape on the front surface side of the other cushion material 1A, the overlapping surface (back surface) of the two cushioning materials 1A. The desired effect can be exhibited by the interaction of F2) due to the uneven shape on the back surface side. For example, FIG. 5 shows an enlarged area A of FIG. Referring to FIG. 5, reference numeral W10, reference numeral D10, and reference numeral C10 are fitting widths and fittings of the back surface side uneven shape of one cushion material 1A and the back surface side uneven shape of the other cushion material 1A, respectively. Depth, fitting gap. According to the laminated cushion material 10A, by adjusting the fitting width W10, the fitting depth D10, and the fitting gap C10 to appropriate values, the amount of material used can be significantly reduced, and for example, the conventional pressure distribution performance can be obtained. It can be improved to the same level or higher, and for example, it can be improved to the same level or higher than the conventional sleeping comfort.

Further, in the laminated cushion material 10A, the back surface F2 of one cushion material 1A and the back surface F2 of the other cushion material 1A face each other. Therefore, the gap (fitting gap C10) formed between the uneven shape on the back surface side of one cushion material 1A and the uneven shape on the back surface side of the other cushion material 1A serves as an air passage, so that high ventilation is achieved. You can get sex. In addition, the complex combination of the concave-convex shape on the back side provides a ventilation effect when turning over, which suppresses the occurrence of stuffiness that occurs inside the laminated cushion material 10A and greatly improves comfort. can do.

Further, the laminated cushion material 10A is lighter than the conventional product group exhibiting the same performance because the amount of material used can be significantly reduced. Therefore, the laminated cushion material 10A is a product that is very easy to handle while having high performance. For example, when the laminated cushion material 10A is a laminated mattress as in the present embodiment, the product is easy to handle while having high bedding performance.

The laminated cushion material 10 includes a plurality of laminated cushion materials 10A. Therefore, the laminated cushion material 10 can obtain the same effect as the laminated cushion material 10A as described above.

FIG. 6 is a plan view, a front view, and a right side view schematically showing the laminated cushion material 20 according to another embodiment of the present invention. In FIG. 6, substantially the same parts as the configurations of FIGS. 1 to 5 use the same reference numerals.

With reference to the plan view of FIG. 6, the laminated cushion material 20 is formed of three laminated cushion materials 20A.

Referring to the front view of FIG. 6, the laminated cushion material 20A includes two cushion materials, a cushion material 1A and a cushion material 1B. In the present embodiment, the cushion material 1A is the cushion material 1. Further, in the present embodiment, the cushion material 1B is a cushion material according to another embodiment of the present invention. The cushion material 1B is a modified example of the cushion material 1A. In the cushion material 1B, the plurality of uneven portions 3 on the back surface side are arranged only in a direction parallel to the width direction DW in a plan view. In the cushion material 1B, the back surface side uneven portion 3 extends in the length direction DL. In the present embodiment, the cushion material 1A and the cushion material 1B are laminated so that the back surface F2 of the cushion material 1A and the back surface F2 of the cushion material 1B face each other. As a result, the two surfaces of the laminated cushion material 20A are formed by the surface F1 of the cushion material 1A and the surface F1 of the cushion material 1B, respectively. In FIG. 6, the uneven shape of the surface F1 of the laminated cushion material 20A is omitted.

According to the laminated cushion material according to the present invention, such as the laminated cushion material 20A, at least one of the two cushion materials can be a single member having an uneven shape on each of the two surfaces. Therefore, according to the laminated cushion material according to the present invention, the structure is simplified while having an uneven shape on each of the two surfaces.

In particular, the laminated cushion material 20A has a gap extending along the DW in the width direction (the back surface side uneven portion 3 of the cushion material 1A) formed by the back surface side uneven shape of the cushion material 1A and the back surface side uneven shape of the cushion material 1B. In addition to the gap formed by the back surface side concave portion 3b of the cushion material 1A, the gap extending along the length direction DL formed by the back surface side uneven shape of the cushion material 1A and the back surface side uneven shape of the cushion material 1B (cushion). Higher air permeability can be obtained by allowing the air passage (the gap formed by the back surface side concave portion 3b) of the back surface side uneven portion 3 of the material 1B). In addition, the complex combination of the concave-convex shape on the back surface side further suppresses the occurrence of stuffiness that occurs inside the laminated cushion material 10A by further obtaining a ventilation effect during operations such as turning over, and improves comfort. It can be greatly improved.

Further, the laminated cushion material 20A is also lighter than the conventional product group exhibiting the same performance because the amount of material used can be significantly reduced. Therefore, the laminated cushion material 20A is also a product that is very easy to handle while having high performance. The laminated cushion material 20 includes a plurality of laminated cushion materials 20A. Therefore, the laminated cushion material 20 can obtain the same effect as the laminated cushion material 20A as described above.

[Manufacturing method of cushion material]
The method for manufacturing a cushion material according to an embodiment of the present invention is a method for manufacturing a cushion material for obtaining the cushion material 1. In the method for producing a cushioning material according to the present embodiment, the cushioning material is formed by performing two-dimensional processing on each of the one-sided surface layer portion and the other-sided surface layer portion of a single base material formed of a foamed resin. In the first processing step of forming the other surface of the above, a removal step of removing the waste material of the base material generated in the first processing step from the base material, and the base material after the removal step. It includes a second processing step of forming the one surface of the cushioning material by performing profile processing.

According to the method for manufacturing a cushion material according to the present embodiment, a beautiful uneven shape is formed on the surface (one surface) F1 of the cushion material 1. Therefore, the method for manufacturing the cushion material according to the present embodiment is suitable for obtaining the cushion material 1.

Hereinafter, a method for manufacturing the cushion material according to the present embodiment will be described with reference to the drawings.

In FIG. 7, in the first processing step of the cushion material manufacturing method according to the present embodiment, the two-dimensionally processed base material 100 is left with the waste materials S1 and S2 generated by the two-dimensional processing. Shown roughly in state.

With reference to FIG. 7, the base material 100 is a single member. In this embodiment, the base material 100 is a rectangular sheet. In the first processing step, two-dimensional processing is performed on each of the one-side surface side surface layer portion 101 and the other surface side surface layer portion 102 of the single base material 100 formed of the foamed resin. Thereby, the primary processed base material 103 (hereinafter, also referred to as “primary processed base material 103”) on which the back surface F2 of the cushion material 1 is formed can be obtained from the base material 100. In the present embodiment, as shown in FIG. 7, each of the one-side surface side surface layer portion 101 and the other surface side surface layer portion 102 is cut into a plane wavy shape by two-dimensional processing. Here, examples of the "two-dimensional machining" include machining (contour machining) in which the contour machine is operated by numerical control.

FIG. 8 is a cross-sectional view schematically showing an example of two-dimensional machining performed in the first machining step of FIG. 7 from the front. In FIG. 8, reference numeral 50 is a contour blade (two-dimensional cutter). In this embodiment, the contour blade 50 extends in the width direction DW of the single substrate 100. The contour blade 50 cuts each of the one surface side surface layer portion 101 and the other surface side surface layer portion 102 of the single base material 100 into a desired shape by numerical control. Note that FIG. 8 shows a state in which the one-side surface layer portion 101 of the single base material 100 is cut.

FIG. 9 schematically shows the two-dimensional machining performed in the first machining step of FIG. 7 from the side surface. In the present embodiment, the contour blade 50 moves along the length direction DL of the base material 100 and moves up and down along the thickness direction DT as shown in FIG. 9 by numerical control. Alternatively, the contour blade 50 is fixed, and the workstation on which the base material 100 is placed is moved along the length direction DL of the base material 100 and moved up and down along the thickness direction DT. As a result, as shown by the solid line in FIG. 7, each of the one surface side surface layer portion 101 and the other surface side surface layer portion 102 of the single base material 100 is cut in a plane wavy shape. As a result, in the first processing step according to the present embodiment, it is possible to obtain the primary processed base material 103 in which the waste materials S1 and S2 of the base material 100 generated in the first processing step are left.

FIG. 10 shows a profile after removing waste materials S1 and S2 from the two-dimensionally processed base material 100 of FIG. 7 in the removal step after the first processing step of FIG. 7, and further in the second processing step. The processed base material 100 is shown schematically.

In the removing step after the first processing step, the waste materials S1 and S2 of the base material 100 generated in the first processing step are removed from the base material 100. With reference to FIG. 10, the primary processed base material 103 from which the waste materials S1 and S2 have been removed is placed on one side surface layer portion 103a and the other side surface side surface layer portion 103b of the primary processed base material 103, respectively. , The back surface F2 of the cushion material 1 is formed.

Further, in the present embodiment, as shown in FIG. 10, the surface F1 of the cushion material 1 is formed by performing profile processing on the primary processed base material 103. In the present embodiment, as shown in FIG. 10, between the one-side surface layer portion 103a and the other-side surface side surface layer portion 103b of the primary processed base material 103 along a predetermined direction (for example, the length direction DL). Cut in two. An uneven shape is formed on the cut surface of the primary processed base material 103 by profile processing. Here, as the "profile processing", for example, in a state where the base material is compressed by the pressing roller, the compressed portion of the base material is in a direction orthogonal to the compression direction of the pressing roller, and the pressing roller is used. A process of cutting along the tangential direction in the pressed portion can be mentioned.

FIG. 11 schematically shows an example of profile processing performed in the second processing step of FIG. 10 from the front. In FIG. 11, reference numeral 60 is a pressing roller. The pressing roller 60 is an upper pressing roller 60a that presses the one surface side surface layer portion 103a of the primary processed base material 103, and a lower pressing roller 60b that presses the other surface side surface layer portion 103b of the primary processed base material 103. And include. The primary processed base material 103 is fed in a predetermined direction in a compressed state by two pressing rollers 60. In the present embodiment, the predetermined direction is the length direction DL. Reference numeral 70 is a contour blade. In the present embodiment, the contour blade 70 extends in the width direction DW of the primary processed base material 103. The contour blade 70 cuts the primary processed base material 103 into two cushion materials 1 between the one side surface layer portion 103a and the other surface side surface layer portion 103b of the primary processed base material 103.

The pressing roller 60 is provided with a plurality of protrusions 61. In this embodiment, the plurality of protrusions 61 are arranged in the extending direction DE of the pressing roller 60. Further, FIG. 12 schematically shows an example of profile processing in the second processing step of FIG. 10 from the side surface. In this embodiment, the plurality of protrusions 61 are also arranged in the circumferential direction DC of the pressing roller 60. The arrangement of the plurality of protrusions 61 can be appropriately selected according to the uneven shape formed on the surface F1 of the cushion material 1.

In the second processing step, the contour blade 70 compresses the primary processed base material 103 in the thickness direction DT of the primary processed base material 103 by the pressing roller 60, and the primary processed base material 103 The compressed portion of is cut in two along the length direction DL of the primary processed base material 103. As shown in FIG. 10, each cut surface of the primary processed base material 103 cut in two has an uneven shape corresponding to the protrusions 61 arranged on the pressing roller 60. As a result, from the primary processed base material 103, as shown in FIG. 10, a secondary processed base material 104 in a state in which the two cushion materials 1 are superposed can be obtained.

The method for producing a cushion material according to the present embodiment includes a separation step of separating the secondary processed base material 104 after the second processing step into two cushion materials. In the present embodiment, in the separation step, the secondary processed base material 104 is separated into two cushion materials 1 along the cut surface formed on the secondary processed base material 104. As a result, according to the method for manufacturing the cushion material according to the present embodiment, two cushion materials 1 can be obtained.

As a method for manufacturing the cushion material, after two-dimensional processing is performed on the base material 100, the waste materials S1 and S2 are left on the primary processed base material 103 which has been primary processed, and the primary processed base material is used. Profile processing can be performed on the material 103. However, in this case, a beautiful uneven shape may not be formed on the surface (one surface) F1 of the profiled cushion material.

On the other hand, in the method for manufacturing a cushion material according to the present embodiment, after removing the waste materials S1 and S2 from the primary processed base material 103 that has been primary processed, the profile is applied to the primary processed base material 103. Perform processing. In this case, the cut surface of the profile-processed secondary processed base material 104 has a beautiful uneven shape. That is, according to the method for manufacturing a cushion material according to the present embodiment, a beautiful uneven shape is formed on the surface (one surface) F1 of the cushion material 1. Therefore, the method for manufacturing the cushion material according to the present embodiment is suitable for obtaining the cushion material 1. Further, according to the present embodiment, two cushioning materials 1 can be manufactured from one single base material 100.

[Manufacturing method of laminated cushion material]
FIG. 13 schematically shows a step of forming the laminated cushion material 10 according to the present embodiment using the secondary processed base material 104 of FIG. 10.

The method for manufacturing the laminated cushion material according to the present embodiment is a preparatory step of preparing the secondary processed base material 104 after the second processing step, and after the preparatory step, the secondary processed base materials 104 to 2 It includes a separation step of separating the cushion material 1 and a stacking step of superimposing the two cushion materials 1 after the separation step.

Referring to FIG. 13, in the method for manufacturing a laminated cushion material according to the present embodiment, two secondary processed base materials 104 are prepared in the preparatory step. Next, in the separation step, one of the two secondary processed base materials 104 is separated into the two cushion materials 1a and 1b, and the other of the two secondary processed base materials 104 is separated into the two cushion materials 1c. , 1d. Next, in the stacking step, the cushion material 1b, the cushion material, and 1c are superposed so that the back surface F2 of the cushion material 1b and the back surface F2 of the cushion material 1c face each other. Further, in the stacking step according to the present embodiment, the cushion material 1a, the cushion material, and 1d are overlapped so that the back surface F2 of the cushion material 1a and the back surface F2 of the cushion material 1d face each other. As a result, according to the method for manufacturing a laminated cushion material according to the present embodiment, two laminated cushion materials 10 can be manufactured.

According to the method for manufacturing a laminated cushion material according to the present embodiment, the preparation step can be a step of preparing one secondary processed base material 104. In this case, the two cushioning materials 1a, 1b (1c, 1d) separated in the separation step are overlapped so that their back surfaces F2 face each other. Thereby, one laminated cushion material 10 can be manufactured.

By the way, in the cushion material 1, the one-sided convex portion (2) includes a one-sided convex portion (2a) and a one-sided concave portion (2b), and the one-sided convex portion (2a) is a cone. The one-sided concave portion (2b) has an inverted cone shape, and the other-sided surface-side concave-convex portion (3) has the other-face-side convex portion (3a) and the other-face-side concave portion (3b). Including, the concave-convex shape on the other side is preferably a plane wavy shape. In this case, either one of the front surface F1 and the back surface F2 of the cushion material 1 can be used as a surface having better pressure dispersibility, and the other surface of the front surface F1 and the back surface F2 of the cushion material 1 can be used. The surface can be used as a surface having better breathability.

FIG. 14 shows an example of the surface-side uneven shape of the cushion material according to still another embodiment of the present invention in an enlarged manner. Further, FIG. 15 is a perspective view showing a part of FIG. 14 in a further enlarged view.

With reference to FIGS. 14 and 15, in the present embodiment, the surface-side uneven portion 2 includes a surface-side convex portion 2a and a surface-side concave portion 2b. The surface side convex portion 2a has a conical shape. The surface side recess 2b has an inverted cone shape. In this case, the surface F1 of the cushion material 1 can be used as a surface having better pressure dispersibility. Further, in the present embodiment, the back surface side uneven portion 3 includes a back surface side convex portion 3a and a back surface side concave portion 3b. The uneven shape on the back surface side is a plane wavy shape. In this case, the back surface F2 of the cushion material 1 can be used as a surface having more excellent breathability. In FIGS. 14 and 15, reference numeral 2a and reference numeral 2b are partially omitted.

According to the present invention, it is possible to provide a cushioning material and a laminated cushioning material having a concave-convex shape on each of the two surfaces and having a simplified structure, and it is suitable for obtaining the cushioning material. A method for manufacturing a cushion material can be provided.

The above has only disclosed some embodiments of the present invention, and various modifications can be made according to the claims. For example, in the above description, the cushioning material and the laminated cushioning material have been described as mattresses assuming that a person lies down, respectively, but they are also applied to the cushioning material and the laminated cushioning material assuming that a person simply sits down. be able to.

1: Cushion material, 1A to 1B: Cushion material, 1a to 1d: Cushion material, 2: Surface side uneven part (one side uneven part), 2a: Surface side convex part (one side convex part), 2b: Surface Side concave part (one side concave part), 3: Back side uneven part (other side uneven part) 3a: Back side convex part (other side convex part), 2b: Back side concave part (other side concave part), 10: Laminated cushion material, 10A: Laminated cushioning material, 20: Laminated cushioning material, 20A: Laminated cushioning material, 50: Contour blade, 60: Pressing roller, 60a to 60b: Pressing roller, 61: Protrusion of pressing roller, 70: Contour blade , 100: Base material, 101: One side surface layer part, 102: One side side surface layer part, 103: Primary processed base material, 104: Secondary processed base material, DL: Length direction, DW: Width direction , DT: Thickness direction, F1: Front surface (one surface), F2: Back surface (other surface), L: Direction, P1: Surface side uneven shape (one side uneven shape) arrangement pitch, P2: Back surface side unevenness Arrangement pitch of shape (concave shape on the other side), S1 to S2: waste material, T: thickness, W: width

Claims (6)

A cushioning material with two sides
The cushion material is a single member formed of foamed resin, and is a single member.
One of the two surfaces has a concavo-convex shape on one side.
The other surface of either of the two surfaces has an uneven shape on the other surface side.
A cushioning material in which the arrangement pitch of the concavo-convex shape on the other side is longer than the arrangement pitch of the concavo-convex shape on the one side. The one-sided concavo-convex shape is composed of a plurality of one-sided concavo-convex portions, and the plurality of one-sided concavo-convex portions have a predetermined direction and an intersecting direction intersecting with the predetermined direction, respectively, in a plan view. Arranged in the direction of
The concavo-convex shape on the other side is composed of a plurality of concavo-convex portions on the other surface side, and the plurality of concavo-convex portions on the other surface side are arranged only in one of the predetermined direction and the intersecting direction in a plan view. The cushioning material according to claim 1, wherein the cushioning material extends in any one of the predetermined direction and the intersecting direction. The one-sided concave-convex portion includes a one-sided convex portion and a one-sided concave portion, the one-sided convex portion has a conical shape, and the one-sided concave portion has an inverted conical shape.
The cushioning material according to claim 2, wherein the concavo-convex portion on the other surface side includes a convex portion on the other surface side and a concave portion on the other surface side, and the concavo-convex shape on the other surface side is a planar wavy shape. Equipped with two cushioning materials,
At least one of the two cushioning materials is the cushioning material according to any one of claims 1 to 3.
The one cushion material and the other cushion material are laminated and arranged so that the at least one other surface of the two cushion materials and the other cushion material face each other. , Laminated cushioning material. The two cushioning materials are the cushioning materials according to any one of claims 1 to 3, respectively.
The one cushion material and the other cushion material are laminated and arranged so that the other surface of the one cushion material and the other surface of the other cushion material face each other. The laminated cushion material according to claim 4. A method for manufacturing a cushion material for obtaining the cushion material according to any one of claims 1 to 3.
The first processing step of forming the other surface of the cushioning material by performing two-dimensional processing on each of the one surface side surface layer portion and the other surface side surface layer portion of the single base material formed of the foamed resin. When,
A removal step of removing the waste material of the base material generated in the first processing step from the base material, and
A second processing step of forming the one surface of the cushioning material by performing profile processing on the base material after the removal step.
A method of manufacturing a cushioning material, including.

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