Body support device
A body support assembly (1) capable of providing a fitting feeling to a user according to the user's body shape by holding the shape thereof matching the user's body shape. The body support assembly (1) comprises a supporting member (4) including a plurality of granulated materials (2) coated with a moisture-curable resin, and a stretchable cloth (3) covering the supporting member (4). The body support assembly (1) is used such that the cloth (3) is allowed to come in contact with the portion of the user's body so as to allow the granulated materials (2) to move relative to one another, and thus the supporting member (4) is deformed in a shape matching the portion of the user's body. Then, the moisture-curable resin is cured. The relative movements of the granulated materials (2) in the supporting member (4) are controlled by a frame (5) embracing an outer peripheral edge of the supporting member (4).
1. Field of the Invention
The present invention relates to a body support assembly which is used when a user sits down in, for example, a seat, a chair or the like and can provide a fitting feeling to the user according to the user's body shape by holding the shape thereof matching the user's body shape.
2. Description of the Related Art
A seat, a chair, such as an automotive seat, an office chair and a wheelchair are manufactured so as to fit an average user. Accordingly, they do not fit properly in some users.
Consequently, various kinds of cushions have been proposed. For example, Japanese Unexamined Patent Publication No. 9-224796 discloses a body support assembly which comprises a molded member employing a structure such that a predetermined amount of granulated materials coated with a moisture-curable urethane prepolymer are covered with a water-permeable material, the water-permeable material having a plurality of openings each smaller than the granulated material, while the water-permeable material is coated with a moisture-impermeable material. The moisture-curable urethane prepolymer and the water-permeable materials are unreactable with each other, exhibiting a low adhesive property relative to each other.
Meanwhile, Japanese Unexamined Patent Publication No. 2000-51255 discloses a body support assembly as a position-upholding tool which comprises an assembly including: a predetermined amount of granulated materials each having elasticity; and moisture-curable resin each having elasticity even after curing, in which a sufficient amount of the moisture-curable resin is mixed with the granulated materials so as to bond one granulated material to another when cured, while the granulated materials can move relative to one another according to a user's body shape before the moisture-curable resin cures.
Those body support assemblies are ones such that the moisture-curable resin cures after the granulated materials such as foamed polyurethanes are moved to take a specific shape as a whole according to a user's body shape, and thus the materials become immobilized in order to hold the specific shape. Those body support assemblies can rapidly and reliably support individual user's body, while the production process thereof is simple, and thus those body support assemblies are especially suitable for medical application to support a patient's head, etc.
Those body support assemblies, however, have the following problems when applied to a seat, a chair or the like to which they are installed in a limited installation area. Namely, those body support assemblies fit to a user's body by allowing the granulated materials such as foamed polyurethanes to move relative to one another, while a supporting member thereof containing the moving granulated materials is flattened by a pressure from the user's body in order to fit thereto, and thus the area of the supporting member is enlarged. Moreover, the enlargement of the area due to this flattening varies according to the individual user's body and the pressure therefrom, so that the resultant shape of the supporting member becomes irregular. Accordingly, those body support assemblies can not be used as they are for a seat or a chair whose size such as width is subjected to predetermined restrictions.
Therefore, it would be advantageous to provide a body support assembly which is able to not only solve the above-explained problems, but also support a user's body reliably while dispersing a pressure from the user's body with superior air permeability, since the product's value thereof can be improved.
The present invention has been made to solve the above problems and it is accordingly an object thereof to provide a body support assembly which can hold its shape matching a user's body shape so that the user can get a fitting feeling in accordance with the user's body shape.
SUMMARY OF THE INVENTIONIn order to attain the above object, according to a first aspect of the present invention, there is provided a body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member, the moisture permeable member being deformable by press and covering the supporting member, the body support assembly being used by allowing: the moisture permeable member to contact a portion of a user's body so as to move the granulated materials; the supporting member to deform in a shape according to the portion of the user's body; and the moisture-curable resin to cure, wherein the body support assembly further comprises a control means for controlling relative movements of the granulated materials, the control means defining a contour of the body support assembly.
The body support assembly employing the above-explained structure is moisturized, and then placed between: a portion of a seat coming in contact with hip, waist, back or the like of a user, namely, the portion of the seat necessary to hold the user; and the user's body. When the user sits down, pressing the body support assembly, the granulated materials in the supporting member move relative to one another and deform the whole shape to the specific shape fitting to a portion of the user such as hip, waist or the like. When the moisture-curable resin cures, the granulated materials with the specific shape are immobilized, and thus the shape matching the individual user's body is held. At that moment, since the relative movements of the granulated materials in the supporting member are controlled, the supporting member does not get out of shape when deformed. Accordingly, the body support assembly is suitable for a seat, a chair or the like. Specifically, since each of the granulated materials has elasticity, the position of the user's body can be reliably supported, while the pressure from the user's body can be dispersed, ensuring superior air permeability.
In the above-explained body support assembly, since the control means may comprise a frame embracing an outer peripheral edge of the supporting member, the granulated materials in the support assembly does not protrude out of the frame, and thus the body support assembly can hold its contour along the frame.
In the above-explained body support assembly, since the moisture permeable member may comprise a molded container having flexibility and moisture permeability, while the control means is arranged so as to cover the supporting member from one side thereof with the molded container and seal off an open side of the molded container, the granulated materials are moved to take the specific shape as a whole in association with the deformation of the molded container, and then immobilized by curing, with the specific shape fitting to the portion of the user such as hip, waist, back or the like. Accordingly, the specific shape matching the individual user's body can be held, and thus the body support assembly can take its shape in accordance with the molded container.
In the above-explained body support assembly, since the moisture permeable member may comprise molded containers each having flexibility and moisture permeability, while the control means is arranged so as to cover the whole circumference of the supporting member with the molded containers, the granulated materials are moved to take the specific shape as a whole in association with the deformation of the molded containers, and immobilized by curing with the specific shape fitting to the portion of the user such as hip, waist, back or the like. Accordingly, the shape matching the individual user's body can be held, and thus the body support assembly can take its shape in accordance with the molded containers.
Also, in the above-explained body support assembly, since the moisture permeable member may comprise a hardening layer of the granulated materials coated with the moisture-curable resin, the granulated materials being hardened thereby in a predetermined shape as a whole, while the control means includes the hardening layer, whereby the granulated materials which are not immobilized yet are surrounded by the hardening layer, and are moved inside thereof relative to one another and deformed. Accordingly, the body support assembly can have a shape matching the hardening layer of an outside surface. Moreover, the supporting member and the moisture permeable member can be made from the same material at a time, the productivity and economical efficiency of the body support assembly can be improved.
Moreover, in the above-explained body support assembly, since the moisture permeable member may comprise flexible sheet members, while the control means is arranged so as to cover both sides of the supporting member with the sheet members, the sheet members being seamed so as to divide the supporting member into a plurality of sections, the granulated materials are allowed to move only within each section, and thus the body support assembly can have a shape according to the one defined by the flexible sheet members.
Alternatively, according to a further aspect of the present invention, the body support assembly may further comprise a volume variable means in the supporting member, the volume variable means defining a contour of the support assembly. The body support assembly employing the above-explained structure is moisturized, and placed between: a portion of a seat coming in contact with hip, waist, back of a user or the like, namely, the portion of the seat necessary to hold the user; and the user's body. When the user sits down, pressing the body support assembly, the granulated materials in the supporting member are moved relative to one another and deform the whole shape thereof to the specific shape fitting to a portion of the user such as hip, waist or the like. When the moisture-curable resin cures, the granulated materials with the specific shape are immobilized, and thus the shape matching the individual user's body is held. At that moment, the granulated materials are flattened in accordance with the amount of depression the granulated materials are subjected to, and thus the whole area thereof is liable to be enlarged. However, by changing the volume of the supporting member in accordance with the flattening of the granulated materials and the enlargement of the area thereof, the body support assembly does not get out of shape. Accordingly, the body support assembly is suitable for the ones having only a limited installation area for installing the body support assembly, such as a seat, a chair or the like. Specifically, since each of the granulated materials has elasticity, the position of the user's body can be reliably supported, while the pressure from the user's body can be dispersed, and thus the body support assembly can have superior air permeability.
In the above-explained body support assembly, the volume variable means may be one which changes a volume of the supporting member by allowing: at least one side of the supporting member to be covered with a molded container having a predetermined shape; the molded container to be formed with a plurality of open-able sections; an open side of the molded container to be covered with a moisture permeable member that is deformable by press; the moisture permeable member to come in contact with a portion of a user's body in order to deform the supporting member and increase a pressure from the granulated materials inside the supporting member so that the plurality of open-able sections are opened, while the granulated materials are discharged from the opened open-able sections. When the granulated materials in the supporting member are pressed and the pressure thereof increases, the open-able sections of the molded container are opened, while the granulated materials are discharged from the opened open-able sections. Accordingly, the volume of the supporting member can be changed so as to hold the contour of the body support assembly, and thus it does not get out of shape when deformed.
Moreover, the volume variable member may comprise the buffering member, provided in the supporting member so as to absorb the change of volume thereof, and thus the volume of the supporting member can be changed by allowing the granulated materials to come into the buffering member, to thereby hold the contour of the body support assembly. Accordingly, the body support assembly does not get out of shape when deformed.
Also, the buffering member may comprise a foamed member.
Further, the supporting member provided with the control means may be arranged to include a foamed member.
Still further, the supporting member may be provided on a backrest of a seat, including a waist supporting member and a shoulder supporting member, and the supporting member may be formed such that thickness thereof decreases toward the shoulder supporting member. Alternatively, the supporting member may comprise a backrest obverse portion placed on a backrest of a seat and a bottom obverse portion placed on a bottom of the seat. Holding members may be provided on the supporting member.
BRIEF DESCRIPTION OF THE DRAWINGS
A first embodiment of the present invention will now be explained with reference to the accompanying drawings FIGS. 1 to 7. As shown in FIGS. 1 to 4, a body support assembly 1 according to this embodiment comprises: a supporting member 4; and a frame 5. The supporting member 4 includes: a plurality of granulated materials 2 coated with a moisture-curable resin; and a cloth 3 as a moisture permeable member which is deformable by press and made from a stretchable knitted fabric, textile fabric, non-woven cloth or a monofilament. The frame 5 is provided in the supporting member 4 as a framework. The frame 5 is essentially octagonal in a plane but bent three-dimensionally. In order to hold in a manner like wrapping a portion of the user's body from right and left sides thereof, the cloth 3 employs a structure such that the size thereof is set to be slightly larger than that of the portion of the user's body so as to provide a well supporting effect. According to this embodiment, the frame 5 serves as a control means for controlling relative movements of the granulated materials 2 within the supporting member 4. Meanwhile, the cloth 3 may be fixed to the frame 5. For example, the cloth 3 may be adhered to the frame 5, or stitched thereonto.
For the granulated material 2 in the above-explained body support assembly 1 is preferred one having adequate elasticity and nonreactive with a moisture-curable resin (described later), or one finished so as not to be reactive with the moisture-curable resin in a non-cured condition. For example, olefin-base granulated materials such as those made from polyethylene, polypropylene or a copolymer thereof with elasticity added thereto by softener or plasticizer, as well as those made from rubber-base materials with elasticity added thereto in a similar way or having elasticity themselves, such as vinyl acetate copolymer, polyvinyl chloride, polystyrene, polyester, polyether, polyurethane, neoprene, polybutadiene, silicon or any other rubber-base material are preferable. Moreover, an elastic material or a gelatinous material that are nonreactive with the moisture-curable resin may also be used therefor.
To be more precise, the following products can be used as the granulated material 2, :COSMOGEL (commercial product made by Cosmo instruments Co., Ltd); MNCS (made by Bridgestone Co., Ltd); ALPHAGEL (made by Seagel Co., Ltd); TORAYPEF (made by Toray Industries, Inc); MITSUFUKU FOAM (made by Mitsufuku Industries Co., Ltd); EXCESEAL (made by Inoac Kabushiki Kaisha); CALSOFT (made by Takiron Co., Ltd); NEOPLEN Rubber (made by Yamamoto Chemical Ind. Co., Ltd); CR Rubber (made by Daiwabo Co., Ltd or Marushinkakou Kabushiki Kaisha); SILICON sponge (made by Chiyoda Gomu Kabushiki Kaisha, Inoac Kabushiki Kaisha or Shinetsu Kagaku Kougyou Kabushiki Kaisha), etc.
Each of the above-described granulated materials 2 may be formed in spherical shape, bar-shape, cubical shape, cuboidal shape, cylindrical shape, discotical shape, or other suitable shapes. It is preferable that the granulated material 2 is formed in corner-free shape, specifically, spherical shape. Moreover, from a standpoint of the elasticity of the body support assembly 1, the granulated material 2 is preferably formed so as to be solid, to have hollows, or to be foamed. In a case where the granulated material 2 is a foamed one, it is preferable to form each of the granulated material 2 to be a closed cell so that the moisture-curable resin (described later) would not permeate inside the granulated material 2. Specifically, one having a skin layer on the surface is suitable.
The size of each granulated material 2 varies depending on: the position to use the body support assembly 1; the material of the granulated material 2; and types or kinds of the moisture-curable resin. Large granulated material 2 results in high permeability to air, but if it is too large, it causes decrease in deformability and surface smoothness thereof, and thus the fitting comfort of the body support assembly 1 would be inferior. Accordingly, the granulated material 2 of less than about 8 cm3 is preferable, more preferably that of 0.125 cm3 or below allows the body support assembly 1 to be easy-to-use and to have a smoothed surface. Alternatively, the granulated material 2 can be made from two or more kinds of above materials having different qualities, shapes, characteristics and/or sizes.
Further, the hardness of the material of the above-explained granulated materials 2 is set to be about 2 kg/cm2 or below under 25% compressive strength test for cushioning soft urethane (JIS K6401 5.4), and preferably, set to be about 1.0 kg/cm2 or below. Still further, compressive residual strain thereof (JIS K 6401 5.5) is set to be about 15% or below, preferably, about 13% or below. In a case where the compressive strength is over 2 kg/cm2 or the compressive residual strain over 15%, the granulated materials 2 are so hard that a distortion thereof would be developed during the use, and thus it is not desirable.
For the moisture-curable resin for coating the above-described granulated materials 2, hydraulic urethane prepolymer is preferable since it easily cures when water is applied. The hydraulic urethane prepolymer is prepolymer having isocianate group in a terminal obtained by a reaction of polyol and polyisocianate. Meanwhile, other moisture-curable resin such as moisture-curable silicon resin may be used. As the moisture-curable resin, one having an appropriate elasticity after cured is preferable. Alternatively, the granulated material 2 may be one which bonds to the moisture-curable resin when the moisture-curable resin cures by the addition of water, or one which is immobilized without bonding to the moisture-curable resin in a state where it is embraced by the moisture-curable resin. A catalytic agent, a fixing agent, an anti-forming agent, an antioxidant, a coloring agent, a thixotropy adding agent, a bulking agent, etc. can be accordingly added to the moisture-curable resin from the standpoints of the hardening time, preservation-stability, acceleration of defoaming when cured, finished color tone and so on. As those additives, well-known compounds can be selected according to the composition of the moisture-curable resin.
In a case where the moisture-curable resin comprises hydraulic urethane prepolymer, bis (2,6-dimethyl molpholino) diethyl ether, triethylene diamine, cyclohexylamine, dimethyl ethanolamine, substitution-molpholine, dimethyl piperazine, or the like can be used as a curing catalyst. In a case where a thixotoropy adding agent is added, maldistribution of the moisture-curable resin can be prevented when the moisture-curable resin is preserved in a mixed condition with the granulated material 2, and thus a state where both the moisture-curable resin and the granulated material 2 are homogeneously mixed can be held. As the thixotoropy adding agent for hydraulic urethane prepolymer, the followings can be used: silica; titanium oxide; organic polyalkylene-modified compound comprising polyalkylene glycol whose hydroxyl end group is treated with a hydroxyl treatment agent, such as polyethylene glycol, polypropylene glycol or a copolymer thereof treated with methyl chloride or a fatty acid; aromatic carboxylic acid esters; benzylidene sorbitols, zytrylidene sorbitols or the like synthesized by acetal reaction of D-sorbitol with aromatic aldehyde. The amount to be used is about 0.01 to 6%, preferably about 0.05 to 3% relative to hydraulic urethane prepolymer.
Hydraulic urethane prepolymer is suitable as the moisture-curable resin since it has the following desirable properties, though they depend on the use thereof, such that: the apparent strength thereof enabling a user's weight to be applied as a load can be obtained in about 3 to 30 minutes' curing time after water is applied; the change of volume thereof due to a reaction is small; harmful effect against human body such as the producing of fever, stimulation or the like seldom occurs; and stability of preservation is high.
Sufficient amount of the above-explained moisture-curable resin is appropriately mixed so that the surfaces of the all granulated materials 2 are coated. Normally, more than about 7.5 g of the moisture-curable resin per 1 litter (volume) of the granulated materials 2 is sufficient, which is preferably about 45 to 420 g. The granulated materials 2 and the moisture-curable resin are mixed by a versatile mixer, a concrete mixer or any other suitable mixer or the like, preferably under an environment in which mixing temperature is 20 degrees centigrade and relative humidity (RH) is 20% or below, such that dry nitrogen gas is filled in a chamber of the above mixer, and then a predetermined amount of the granulated materials 2 is put therein and stirred while a predetermined amount of the moisture-curable resin is mixed therewith, until they are mixed in a homogeneous state.
After mixing, each of the granulated materials 2 is coated with the sufficient amount of the moisture-curable resin for sticking one granulated material 2 to another. Each of the granulated materials 2 is gathered in a mass by the non-cured moisture-curable resin, but in a condition such that each of them can move relative to one another. The mixture of the granulated materials 2 and the moisture-curable resin can be preserved so as to remain non-cured, by storing it in a moisture-proofed one such as a packaging bag or sheet including an aluminum foil, a box and a can.
The cloth 3 is made for example from: synthetic fibers of polyester, polypropylene, polyethylene, polyacrylamide, polyurethane, styrene-isoprene-styrene-copolymer (SIS), polyamide or other kinds of synthetic fibers; regenerated fibers of rayon, cotton, linen or the like; and inorganic fibers such as natural fibers, glass fibers, etc. A material of the cloth 3 reactive with the moisture-curable resin or having a large moisture content may be subjected to preliminary surface treatment to have non-reactivity, or dried to be dehydrated. For hydraulic urethane prepolymer, a preferable material of the cloth 3 is one which does not react with the none-cured urethane prepolymer, such as polyester, polypropylene, polyethylene, polyurethane, SIS or the like. Specifically, fibers of polyester, polypropylene, polyethylene, polyurethane or SIS, each having heat sealing characteristic, or blended fabrics of either one of them are preferred. Those materials are formed in a knit, textile, non-woven cloth, molten-net or the like, but it is desirable to form them flexible and extendible enough to fit well to the contour of the portion of the user's body when applied. For such flexibility and extendibility, one having at least 15% elongation percentage in either direction of longitudinal or transversal directions is preferable. Less than that percentage of elongation may result in a poor compatibility with the user's body when deforming its shape.
The frame 5 is made from a material having a certain level of rigidity and elasticity such as a steel-made wire, synthetic resins and so on. For example, the steel-made wire may be three dimensionally bent in a desired shape and both ends thereof may be jointed by a caulking portion 5A so as to shape the frame 5. Alternatively, the frame 5 may be made from a synthetic resin such as foamed polystyrene which is formed in a similar shape.
The body support assembly 1 of this embodiment is put into a non-illustrated moisture-proof bag and sealed therein. Consequently, the granulated materials 2 are not exposed to moisture in this sealed condition, and thus the curing of the moisture-curable resin is certainly prevented, while the moisture-curable resin coating the granulated materials 2 can be cured in a short time by opening the moisture-proof bag and then applying water or spraying a catalyst solution thereto so as to allow the moisture-curable resin to be exposed to moisture. As shown in
Next, operations of the body support assembly 1 employing the above-explained structure will now be explained. First of all, the body support assembly 1 is taken out from the moisture-proof bag (not shown). The moisture-curable resin starts curing when water is forced into the cloth 3 (the moisture permeability member of the body support assembly 1) by pressingly putting an atomist spray or the like to the cloth 3. Then, the frame 5 is placed on the backrest 11A of the seat 11, while the cover sheet is put over there if necessary.
Next, when the user (not shown) sits down while pressing his/her body to the body support assembly 1, the stretchable cloth 3 stretches, while the granulated materials 2 in the supporting member 4 move relative to one another and rapidly deform the whole shape thereof to the specific shape fitting to the user's body. When the moisture-curable resin coating the surfaces of the granulated materials 2 cures in a short time (3-5 minutes), the granulated materials 2 are immobilized and thus the specific shape thereof can be held. At the central portion of the supporting member 4, the granulated materials 2 become thinner corresponding to the amount of the pressure from the user and thus the planer shape of the supporting member 4 is urged to be changed by the granulated materials 2, but the supporting member 4 does not protrude outside the frame 5 since the supporting member 4 is embraced by the frame 5. As a result, both right and left edges of the supporting member 4 inflate and hold the user's body in a manner like wrapping the user's body from right and left sides.
Since the body support assembly 1 can instantly and easily deform its shape matching the individual user's body shape while the portion of the body support assembly 1 facing the seat 11 can deform its shape smoothly in accordance with the seat 11 and then harden, the body support assembly 1 can be placed without a displacement relative to the seat 11. Moreover, whilst the body support assembly 1 holds its shape by allowing the moisture-curable resin coating the granulated materials 2 to cure, yet it can have an appropriate softness as well as hardness since each granulated material 2 has elasticity. Further, it can also have an air permeability so as to essentially prevent the user from getting sweaty when used for a long time since there is a space between each of the granulated materials 2. Therefore, it can provide a comfortable holding and cushioning performance to the user.
Moreover, since the body support assembly 1 employs a simple structure such that the granulated materials 2 coated with the moisture-curable resin are covered by the cloth 3 while the frame 5 is used as a framework, it can be simply designed, and is excellent in mass-productivity. Therefore, the body support assembly 1 can be manufactured at a low-cost. Further, since the body support assembly 1 is preserved in the moisture-proof bag and sealed therein, the granulated materials 2 can be prevented from getting immobilized due to the granulated materials 2 sticking to one another. Accordingly, the supporting member 4 can be prevented from becoming solid unless the body support assembly 1 is taken out of the moisture-proof bag, and thus the body support assembly 1 has excellent transporting, distributing and storing abilities, and is extremely easy to handle.
As explained above, according to this embodiment, the body support assembly 1 comprising: a supporting member 4 including the plurality of granulated materials 2 coated with a moisture-curable resin; and a cloth 3 as a moisture permeable member being deformable by press, the cloth 3 covering the supporting member 4, the body support assembly 1 being used by allowing: the moisture permeable member to contact a portion of a user's body so as to move the granulated materials 2 relative to one another; the supporting member 4 to deform in a shape according to the portion of the user's body; and the moisture-curable resin to cure, wherein the body support assembly 1 further comprises a frame 5 as a control means for controlling relative movements of the granulated materials 2, the frame 5 defining a contour of the supporting member 4. Thus, the relative movements of the granulated materials 2 in the supporting member 4 are controlled by allowing the frame 5 to surround the outer peripheral edge of the supporting member 4. The body support assembly 1 is moisturized, and set between the seat 11 and the user's body. When the user sits down while pressing the body support assembly 1, the granulated materials 2 in the supporting member 4 move relative to one another and deform the whole shape thereof to the specific shape fitting to the portion of the user's body such as hip, waist or the like. When the moisture-curable resin cures, the granulated materials 2 with the specific shape are immobilized, and thus the shape matching the individual user's body is held. Since the relative movements of the granulated materials 2 in the supporting member 4 are controlled, the supporting member 4 does not get out of shape when deformed. Accordingly, the body support assembly 1 is suitable for a seat, a chair or the like whose width is subjected to restrictions. Specifically, since each of the granulated materials 2 has elasticity, the position of the user's body can be reliably supported and the pressure from the user's body can be dispersed, and the body support assembly 1 can have superior air permeability.
Next, a second embodiment of the present invention will now be explained with reference to
In the above-explained body support assembly 1, the granulated materials 2 and the moisture-curable resin are the same as ones in the first embodiment. Further, the body support assembly 1 of this embodiment is also put into a non-illustrated moisture-proof bag and sealed therein.
Next, operations of the body support assembly 1 employing the above-explained structure will now be explained. First of all, the body support assembly 1 is taken out from the moisture-proof bag (not shown). The moisture-curable resin coating the granulated materials 2 starts curing when water is applied to the molded container 21 by spraying or the like. Then, a cover sheet is put over the molded container 21 if necessary, while the body support assembly 1 is set at the automotive seat 11 in the similar way explained in the first embodiment so that the molded container 21 of the body support assembly 1 faces up. Next, when the user sits down while pressing the user's body portion(s) such as waist, back, legs, etc. to the body support assembly 1, the molded container 21 deforms, while the granulated materials 2 in the supporting member 4 move relative to one another, and rapidly deform the whole shape to the specific shape fitting to the user's body and hold this specific shape by being immobilized when the moisture-curable resin coating the surfaces of granulated materials 2 cures in a short time (3-5 minutes). The shape of the supporting member 4 is urged to be changed in accordance with the amount of press the granulated materials 2 are subjected to, but the supporting member 4 does not protrude out of the molded container 21 since one side of the supporting member 4 is covered by the molded container 21 so that relative movements of the granulated materials 2, which occurs in a direction toward the one side and in a lateral direction relative to a bottom surface 21B embraced by a peripheral wall 21 A of the molded container 21, is controlled. Accordingly, the body support assembly 1 can be deformed in a shape controlled by the molded container 21. Moreover, whilst the body support assembly 1 is one which holds its shape by allowing the moisture-curable resin coating the granulated materials 2 to cure, it can have an appropriate softness as well as hardness since each granulated material 2 has elasticity, while it can have an air permeability so as to essentially prevent the user from getting sweaty when used for a long time since there is a pore space among the granulated materials 2. Therefore, it can provide a comfortable holding and cushioning performance to the user.
Next, a third embodiment of the present invention will now be explained with reference to
Next, a fourth embodiment of the present invention will now be explained with reference to
The body support assembly 1 of the fourth embodiment can be used in the same way as explained in the second embodiment. Specifically, since the tapered portions 25 having smooth slopes are formed on the upper and lower ends of the molding portion 24, a bump between the body support assembly 1 and the automotive seat 11 is not essentially created when the body support assembly 1 is placed on the automotive seat 11. Therefore, the user essentially does not feel uncomfortable.
Next, a fifth embodiment of the present invention will now be explained with reference to FIGS. 13 to 17. The body support assembly according to the fifth embodiment essentially employs the same structure as that of the second embodiment, and thus the same reference numbers will denote the same structure portions, while detailed explanations thereof will be omitted. In the body support assembly 1 of this embodiment, the supporting member 4 employs a structure such that the plurality of granulated materials 2 coated with the moisture-curable resin are contained in a molded container 26 having flexibility, while open side of the molded container 26 is covered by a film 23 or the like. In this embodiment, the control means for controlling the relative movements of the granulated materials 2 in the supporting member 4 comprises: the molded container 26 covering one side of the supporting member 4; and the film 23 or the like covering the open side thereof. The molded container 26 comprises a plastic mesh material having flexibility and moisture-permeability. As shown in
Moreover, in the body support assembly 1 according to this embodiment, since the supporting member 4 is placed on the backrest 11A of the seat 11 while the hold portions 27 are formed on the right and left sides of the molded container 26, the body support assembly 1 can hold the back of the user from both right and left sides. Accordingly, the user can sit down in a condition without a stress applied to the muscles from the waist to the back, and thus a stress to the waist of the user can be reduced.
Meanwhile, since the body support assembly 1 according to this embodiment employs a complicated form such that it has the molded container 26 having flexibility or fragility, the hold portions 27 might be deformed during the preservation and transportation thereof. In this connection, the body support assembly 1 may be covered by a container which is made from, for example, expanded polystyrene so that the deformation of the molded container 26 can be prevented. As shown in
Next, a sixth embodiment of the present invention will now be explained. As shown in
Operations of the body support assembly 1 employing the above-explained structure will now be explained. First of all, the body support assembly 1 is taken out from the moisture-proof bag (not shown). The moisture-curable resin starts curing when water is applied into the cloths 3 (the moisture permeability member of the body support assembly 1) by, for example, spraying the water to the cloth 3. The frame 5 is placed on the backrest 11A, and a cover sheet is put over there.
Next, when the user sits down while pressing the user's body to the body support assembly 1, the stretchable cloths 3 elongates, while the granulated materials 2 in the supporting member 4 move relative to one another, and rapidly deform the whole shape to the specific shape fitting to the user's body and hold this specific shape by being immobilized when the moisture-curable resin coating the surfaces of granulated materials 2 cures in a short time (3-5 minutes). At the central portion of the supporting member 4, the granulated materials 2 become thinner in accordance with the amount of press they are subjected to, and thus the planer shape of the supporting member 4 is urged to be changed by the granulated materials 2. The granulated materials 2, however, do not protrude out of the sections 4A since they are divided by the sections 4A. As a result, both right and left edges of the supporting member 4 only inflate and hold the user's body so as to wrap the user's body.
Since the body support assembly 1 can instantly and easily deform its shape to the specific shape matching the individual user's body while the portion of the body support assembly 1 facing the seat 11 can deform its shape and hardens corresponding to the shape of the seat 11 smoothly, the body support assembly 1 can be essentially placed without a displacement. Moreover, the body support assembly 1 holds its shape by allowing the moisture-curable resin coating the granulated materials 2 to cure, but it can have an appropriate softness as well as hardness since each granulated material 2 has elasticity, while it can have an air permeability so as to essentially prevent the user from getting sweaty when used for a long time. Therefore, it can provide a comfortable holding and cushioning.
Further, the body support assembly 1 can be simply designed and have good mass-productivity since the body support assembly 1 employs a simple structure such that the granulated materials 2 coated with the moisture-curable resin are covered by the stretchable cloths 3. Therefore, the body support assembly 1 can be simply manufactured at a low-cost. Still further, since the body support assembly 1 is preserved while being put into the moisture-proof bag and sealed therein, the granulated materials 2 can be prevented from sticking one another and being immobilized. Accordingly, the supporting member 4 can be prevented from becoming solidified as long as putting the body support assembly 1 in the moisture-proof bag, and thus the body support assembly 1 has excellent transporting capability, distributing ability and storing ability.
As explained above, the control means of this embodiment, the control means is arranged so as to cover both sides of the supporting member 4 with cloths 3 as the sheet members, the cloths 3 being seamed so as to divided the supporting member 4 into a plurality of sections 4A for controlling the relative movements of the granulated materials 2, the supporting member 4 containing a plurality of the granulated materials 2. The granulated materials 2 in the supporting member 4 can only move inside the respective sections 4A, and thus the body support assembly 1 can have a shape matching the flexible cloths 3. Specifically, since each of the granulated materials 2 has elasticity, the position of the user's body can be reliably supported, while the pressure from the user's body can be dispersed and thus the body support assembly 1 can have superior air permeability.
A seventh embodiment of the present invention will now be explained in detail. As shown in
The body support assembly 1 according to this embodiment can be manufactured as follows: as shown in
Like the second to seventh embodiments, the control means can be in various modes as long as it can control the relative movements of the granulated materials 2 within the supporting member 4.
Next, an eighth embodiment of the present invention will now be explained in detail with reference to
With the structure such that the supporting member 4 includes the foamed member 41 inside thereof, when the user sits down while pressing the user's body to the body support assembly 1, the molded container 21 deforms, and the granulated materials 2 in the supporting member 4 move relative to one another, while the foamed member 41 contracts and rapidly deforms in the specific shape fitting to the user's body. The moisture-curable resin coating the surfaces of the granulated materials 2 cures in a short time (3-5 minutes), and thus the granulated materials 2 are immobilized. Accordingly, the foamed member 41 is allowed to hold the deformed shape, and thus the body support assembly 1 can hold the deformed shape. Specifically, the body support assembly 1 of this embodiment has excellent flexibility since it includes the foamed member 41 as well as the granulated materials 2 each having elasticity. Further, the amount of the granulated materials 2 coated with the relatively expensive and delicate moisture-curable resin can be reduced.
Next, a ninth embodiment of the present invention will now be explained in detail with reference to FIGS. 24 to 27. In the body support assembly 51 according to this embodiment, the supporting member 4 employs a structure such that the plurality of granulated materials 2 coated with the moisture-curable resin are contained between molded containers 52, 53 each having deformability. The molded container 52 forming one side (rear side) of the supporting member 4, while the molded container 53 forming the other side (front side) of the supporting member 4. The molded containers 52, 53 have moisture permeability and comprise mesh materials made from flexible synthetic resins. As shown in
In the body support assembly 51, the granulated materials 2 and the moisture-curable resin are the same as ones in the first embodiment. Further, the body support assembly 51 according to this embodiment is also put into a non-illustrated moisture-proof bag and sealed therein when preserved. Accordingly, the granulated materials 2 are not moisturized in this put-in condition, and thus hardening thereof is certainly prevented, while the moisture-curable resin coating the granulated materials 2 can cure in a short time by applying water, spraying a catalyst solution so as to be moisturized when the moisture-proof bag is opened. By putting over a cover sheet (not shown) which is proper for an automotive seat, for example, a stretchable fabric, the body support assembly 51 is completely hidden, and thus the significantly favorable appearance in this equipping condition can be obtained. The body support assembly 51 according to this embodiment is placed on the seat cover 62 covering the automotive seat 61. Meanwhile, reference number 63 denotes a headrest.
Next, operations of the body support assembly 51 employing the above-explained structure will now be explained. First of all, the body support assembly 51 is taken out from the moisture-proof bag (not shown). The moisture-curable resin starts curing (
As explained above, the body support assembly 51 of this embodiment comprising: a supporting member including a plurality of granulated materials 2 coated with a moisture-curable resin; and molded containers 52, 53 as moisture permeable members being deformable by press and covering the supporting member 4, the body support assembly 51 being used by allowing: the molded members 52, 53 to contact a portion of a user's body so as to move the granulated materials 2 relative to one another; the supporting member 4 to deform in a shape according to the portion of the user's body; and the moisture-curable resin to cure, wherein the body support assembly 51 further comprises a volume variable means in the supporting member 4, the volume variable means defining a contour of the body support assembly 51. The volume variable means changes a volume of the supporting member 4 by allowing: at least one side of the supporting member 4 to be covered with a molded container 52 having a predetermined shape; the molded container 52 to be formed with a plurality of open-able sections; open side of the molded container 52 to be covered with the molded container 53 as a moisture permeable member that is deformable by press; the molded container 53 to come in contact with a portion of a user's body in order to deform the supporting member 4 and increase a pressure from the granulated materials 2 inside the supporting member 4 so that the plurality of open-able sections 55 are opened, while the granulated materials 2 are discharged from the opened open-able sections 55. The outer form of the body support assembly 1 can be defined by employing the above-explained structure. When the granulated materials 2 in the supporting member 4 are depressed and the pressure from the granulated materials 2 increases, the open-able sections 55 of the molded container 52 are opened and thus the granulated materials 2 are discharged from the opened open-able sections 55 and thus the volume of the supporting member 4 is changed in order to keep the outer form of the body support assembly 1. Accordingly, the supporting member 4 does not get out of shape. Therefore, the body support assembly 51 is suitable for a seat, a chair or the like. Specifically, since each of the granulated materials 2 has elasticity, the position of the user's body can be reliably supported, while the pressure from the user's body can be dispersed and thus the body support assembly 51 can have superior air permeability. Moreover, the user can get a comfortable sitting feeling by the holding member 54.
Further, a tenth embodiment of the present invention will now be explained in detail with reference to FIGS. 28 to 31. In the body support assembly 71 according to this embodiment, the supporting member 4 employs a structure such that the granulated materials 2 coated with the moisture-curable resin are contained between molded containers 72, 73. The molded container 72 forms one side (lower side) of the supporting member 4, while the molded container 73 forms the other side (upper side) of the supporting member 4. The molded containers 72, 73 are deformable or fragile, each having moisture permeability and comprising a mesh material made from flexible synthetic resins. As shown in
The volume variable means according to this embodiment comprises: the molded container 72 with a predetermined shape which covers at least one side of the supporting member 4; the open-able sections 75 formed on the molded container 72; and the molded container 73 which covers the open side of the molded container 72 as a flexible and deformable moisture-permeable member. The volume variable means changes the volume of the supporting member 4 by: increasing the pressure from the granulated materials 2 in the supporting member 4 by allowing the molded container 73 to be put the portion of the user's body in order to be pressed and deformed; opening the open-able sections 75 by the increased pressure; and discharging the granulated materials 2 from the open-able sections 75.
In the body support assembly 71, the granulated materials 2 and the moisture-curable resin are the same in the first embodiment. Further, the body support assembly 71 according to this embodiment is also put into a non-illustrated moisture-proof bag and sealed therein when stored. Accordingly, the granulated materials 2 are not moisturized in this put-in condition, and thus immobilization thereof is certainly prevented, while the moisture-curable resin coating the granulated materials 2 can cure in a short time by adding water, spraying a catalyst solution so as to allow the moisture-curable resin to be moisturized when the moisture-proof bag is opened. By putting over a stretchable cloth (not shown), the appearance of the body support assembly 71 can be improved. The above-explained body support assembly 71 according to this embodiment is placed in, for example, a shoe so as to align to a planer arch of the user's foot.
Next, operations of the body support assembly 71 employing the above-explained structure will now be explained. First of all, the body support assembly 71 is taken out from the moisture-proof bag (not shown). The moisture-curable resin starts curing (
Next, an eleventh embodiment of the present invention will now be explained in detail with reference to
As explained in this embodiment, the supporting member 4 is placed on the backrest 11A of the seat 11, it has the waist supporting member 102 and the shoulder supporting member 101 while it becomes thinner to the shoulder supporting member 101, and thus an inter space between the shoulder U1 of the user U and the backrest portion 11A is not essentially created. Therefore, the head of the user U can be stably supported by the headrest.
Next, a twelfth embodiment of the present invention will now be explained in detail with reference to
As explained, since the supporting member 4 has the backrest obverse portion 81 placed on the backrest 11A of the seat 11 and the bottom obverse portion 82 provided on the bottom 14 of the seat 11, the body portion of the user U from the waist U2 to the shoulder U3 can be held, while an area to be supported by the body support assembly 1 is enlarged, and thus a stress partially applied to the waist U2 can be reduced. Therefore, a generation of a backache due to driving a car in a driving position can be prevented.
Next, a thirteenth embodiment of the present invention will now be explained in detail with reference to
In this embodiment, the control means comprises the frame 5 embracing the outer peripheral edge of the supporting member 4, and thus the body support assembly 1 can hold its contour along the frame 5.
Next, a fourteenth embodiment of the present invention will now be explained in detail with reference to
As explained above, since the supporting member 4 is placed on the backrest 11A of the seat 11, while the hold portions 111 are provided on the right and left ends of the supporting member 4 in this embodiment, the back of the user U can be held from both sides thereof and thus the user U can sit down without a stress to his/her muscle from the waist to the shoulder thereof. Therefore, the stress to the waist can be reduced.
Next, a fifteenth embodiment of the present invention will now be explained in detail with reference to FIGS. 39 to 41. The body support assembly 1 according to this embodiment has a frame 5 as the control means, and placed on the bottom 14 by laying or the like. Thicker hold portions 121 are provided on the right and left ends of the supporting member 4. The hold portions 121 are formed such that the right and left ends of the supporting member 4 are bent upward with angles respectively and aligned so as to hold the body of the user U from the right and left thereof. Moreover, as shown in
As explained above, the supporting member 4 is placed on the bottom 14 of the seat 11 while the hold portions 121 are provided on the right and left ends of the supporting member 4 in this embodiment, the hip U3 of the user U can be held from the right and left thereof, and thus the user U can correctly hold a seating position.
The above-explained embodiments are intended to illustrate the present invention, not to limit the scope of the present invention, and various embodiments and changes may be made thereonto without departing from the broad spirit and scope of the invention. For example, in order to change the volume of the supporting member, the granulated materials coated with the moisture-curable resin may be covered with a moisture permeable member deformable by press such as the stretchable cloth 3, while the gathering portion may be provided on the ends of the cloth 3. Further, as the deformable-by-press moisture permeable member, any material can be used as long as it is deformable by press, having moisture permeability, and thus it is not limited to a cloth or a container made from plastic, but can be paper, natural or artificial leather, etc. Further, the material may be one which essentially does not have moisture permeability but is given the property by being formed with openings, by a needle punch or the like. A film or sheet made from synthetic resin may be used as the material in that case.
Claims
1. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a control means for controlling relative movements of said granulated materials, said control means defining a contour of said body support assembly; and
- said control means comprises a frame embracing an outer peripheral edge of said supporting member.
2. (Canceled)
3. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a control means for controlling relative movements of said granulated materials, said control means defining a contour of said body support assembly;
- said moisture permeable member comprises a molded container having flexibility and moisture permeability; and
- said control means is arranged so as to cover said supporting member from one side thereof with said molded container and seal off an open side of said molded container.
4. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a control means for controlling relative movements of said granulated materials, said control means defining a contour of said body support assembly;
- said moisture permeable member comprises molded containers each having flexibility and moisture permeability; and
- said control means is arranged so as to cover a whole circumference of said supporting member with said molded containers.
5. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a control means for controlling relative movements of said granulated materials, said control means defining a contour of said body support assembly;
- said moisture permeable member comprises a hardening layer of said granulated materials coated with said moisture-curable resin, said granulated materials being hardened in a predetermined shape as a whole; and
- said control means has said hardening layer.
6. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member being deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a control means for controlling relative movements of said granulated materials, said control means defining a contour of said body support assembly;
- said moisture permeable member comprises moisture permeable flexible sheet members; and
- said control means is arranged so as to cover both sides of said supporting member with said sheet members, said sheet members being seamed in grids so as to divide said supporting member into a plurality of sections.
7. The body support assembly according to claim 4, wherein said body support assembly further comprises a volume variable means for said supporting member, said volume variable means defining a contour of said supporting member.
8. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a volume variable means in said supporting member, said volume variable means defining a contour of said body support assembly;
- said volume variable means changes a volume of said supporting member by allowing: at least one side of said supporting member to be covered with a molded container having a predetermined shape; said molded container to be formed with a plurality of open-able sections; an open side of said molded container to be covered with a deformable-by-press moisture permeable member; said moisture permeable member to come in contact with a portion of a user's body in order to deform the supporting member and increase a pressure from said granulated materials inside said supporting member so that said plurality of open-able sections are opened, while said granulated materials are discharged from said opened open-able sections.
9. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a volume variable means in said supporting member, said volume variable means defining a contour of said body support assembly; and
- said volume variable means is provided inside said supporting member and serves as a buffering member absorbing a change of volume of said supporting member.
10. The body support assembly according to claim 9, wherein said buffering member comprises a foamed member.
11. A body support assembly comprising: a supporting member including a plurality of granulated materials coated with a moisture-curable resin; and a moisture permeable member being deformable by press and covering said supporting member, said body support assembly being used by allowing: said moisture permeable member to contact a portion of a user's body so as to move said granulated materials relative to one another; said supporting member to deform in a shape according to the portion of the user's body; and said moisture-curable resin to cure, wherein:
- said body support assembly further comprises a control means for controlling relative movements of said granulated materials, said control means defining a contour of said body support assembly; and
- said supporting member is arranged to include a foamed member so as to change a volume thereof.
12. The body support assembly according to claim 1, wherein:
- said supporting member is provided on a backrest of a seat, said supporting member comprising a waist supporting member and a shoulder supporting member; and
- said supporting member is formed such that thickness thereof decreases toward said shoulder supporting member.
13. The body support assembly according to claim 1, wherein said supporting member comprises:
- a backrest corresponding member placed on a backrest of a seat; and
- a bottom corresponding member placed on a bottom of said seat.
14. (Canceled)
15. The body support assembly according to claim 1, wherein:
- said supporting member is placed on a backrest of a seat; and
- holding members are formed on right and left ends of said supporting member.
16. The body support assembly according to claim 1, wherein:
- said supporting member is placed on a bottom of a seat; and
- holding members are formed on right and left ends of said supporting member.
Type: Application
Filed: Dec 10, 2002
Publication Date: Feb 24, 2005
Inventors: Seiya Matsushima (Niiza-shi), Makoto Yoshitake (Niiza-shi)
Application Number: 10/494,088