CUSHION AND MATTRESS

A cushion and a mattress are provided with a large number of options for an adjustable resilient characteristic, and it is possible to reduce the frequency of replacement of an old cushion being used with another new cushion. In the cushion, an upper cushion and a lower cushion each of which is formed with a filament three-dimensional bonded member are arranged to overlap each other in an up/down direction, the upper cushion and the lower cushion are interchangeable in position and are reversible in vertical orientation and at least three of the resilient characteristic of the upper surface of the upper cushion, the resilient characteristic of the lower surface of the upper cushion, the resilient characteristic of the upper surface of the lower cushion and the resilient characteristic of the lower surface of the lower cushion are different from each other.

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Description
TECHNICAL FIELD

The present invention relates to a cushion which can be utilized for various applications and a mattress which uses a cushion.

BACKGROUND ART

As a cushioning material which can be used in a mattress, a pillow or the like, attention has focused on a filament three-dimensional bonded member (three-dimensional network structure) obtained by three-dimensionally fusing filaments made of a thermoplastic resin or a thermoplastic elastomer.

Advantageously, the cushioning material as described above is easy to recycle, is steam resistant and is washable in water. Furthermore, the diameter of the filaments and the number of filaments supplied are adjusted, and thus the resilient characteristics of the cushion (degree of high resilience or low resilience) can be easily adjusted, with the result that it is advantageously possible to manufacture a cushion which suits the body and the preferences of a user.

As a method for manufacturing such a cushion, for example, Patent Document 1 discloses a method for manufacturing a cushion which is gradually harder from the side of a front surface to the side of a back surface by arranging nozzles having different hole diameters in an up/down direction (thickness direction). Patent Document 2 also discloses a method for manufacturing a cushion the hardness of which is adjusted to correspond to parts of a body such as a shoulder portion and a buttock portion by adjusting the drawing speed of a filament three-dimensional bonded member.

RELATED ART DOCUMENT Patent Document

Patent Document 1: Japanese Unexamined Patent Application Publication No. 2006-97223

Patent Document 2: Japanese Unexamined Patent Application Publication No. 2010-154965

Disclosure of the Invention Problems to be Solved by the Invention

Even if a cushion has optimal resilient characteristics for a user when the user first begins to use the cushion, the muscle mass and the weight of the user may be changed over a long period of time due to muscle training and the like. In such a case, the optimal resilient characteristics for the user are changed, and thus it is necessary to interchange cushions.

Since the cushion disclosed in Patent Document 1 has the soft front surface and the hard back surface, the front surface and the back surface are reversed, and thus the cushion can be used in two ways. However, for the cushion, there is only one option for adjusting the resilient characteristics. Hence, when the body shape of the user such as the weight and the muscle mass is changed, and thus the optimal resilient characteristics are changed, it is disadvantageously necessary to purchase a new cushion to replace the cushion being used with the new cushion except when the front surface and the back surface can be accidentally adjusted to appropriate resilient characteristics by reversing them.

In view of the problem as described above, an object of the present invention is to provide: a cushion in which, for example, even when the weight, the muscle mass and the like of a user are changed, a large number of options for an adjustable resilient characteristic are provided, and it is possible to reduce the frequency of replacement of an old cushion being used with another new cushion; and a mattress which uses the cushion described above.

Means for Solving the Problem

A cushion according to the present invention includes: an upper cushion; and a lower cushion, each of the upper cushion and the lower cushion is formed with a filament three-dimensional bonded member, the upper cushion and the lower cushion are arranged to overlap each other in an up/down direction, the upper cushion and the lower cushion are interchangeable in position, and are reversible in vertical orientation, and at least three of a resilient characteristic of an upper surface of the upper cushion, a resilient characteristic of a lower surface of the upper cushion, a resilient characteristic of an upper surface of the lower cushion and a resilient characteristic of a lower surface of the lower cushion are different from each other.

A mattress according to the present invention that supports a user in an upper sleeping posture includes: a plurality of cushions that are aligned in a height direction of the user, and at least one of the plurality of cushions are specific cushions each being the cushion of the above configuration.

Specifically, in the above configuration, the plurality of cushions may include: as the specific cushions, a shoulder cushion for supporting a shoulder portion, a lumbar cushion for supporting a lumbar portion and a leg cushion for supporting a leg portion, and all the upper cushions and the lower cushions of the shoulder cushion, the lumbar cushion and the leg cushion may be identical in outer shape. The “identical in outer shape” in the present application is a concept which indicates that the overall outer shape is substantially the same as the size thereof with no consideration given to slight projections and recesses in the surface of the filament three-dimensional bonded member and air gaps thereinside.

A cushion according to the present invention includes: a predetermined number of constituent cushions, the predetermined number being three or more, each of the predetermined number of constituent cushions is formed with a filament three-dimensional bonded member such that resilient characteristics of an upper surface and a lower surface of each of the predetermined number of constituent cushions are equivalent, the predetermined number of constituent cushions are arranged to overlap each other in an up/down direction, resilient characteristics of the predetermined number of constituent cushions are different from each other, and all the predetermined number of constituent cushions are identical in outer shape and are interchangeable in position.

A mattress according to the present invention that supports a user in an upper sleeping posture, the mattress includes: a plurality of cushions that are aligned in a height direction of the user and at least one of the plurality of cushions is the cushion of the above configuration.

A mattress according to the present invention that supports a user in an upper sleeping posture includes: a plurality of cushions that are aligned in a height direction of the user, the plurality of cushions include a shoulder cushion for supporting a shoulder portion, a lumbar cushion for supporting a lumbar portion and a leg cushion for supporting a leg portion, the shoulder cushion includes a predetermined number of shoulder constituent cushions, the predetermined number being three or more, each of the predetermined number of shoulder constituent cushions is formed with a filament three-dimensional bonded member such that resilient characteristics thereof are different from each other, the predetermined number of shoulder constituent cushions are arranged to overlap each other in an up/down direction, the lumbar cushion includes the predetermined number of lumbar constituent cushions, each of the predetermined number of lumbar constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics thereof are different from each other, the predetermined number of lumbar constituent cushions are arranged to overlap each other in the up/down direction, the leg cushion includes the predetermined number of leg constituent cushions, each of the predetermined number of leg constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics thereof are different from each other, the predetermined number of leg constituent cushions are arranged to overlap each other in the up/down direction and all the shoulder constituent cushions, the lumbar constituent cushions and the leg constituent cushions are identical in outer shape.

Advantages of the Invention

In a cushion according to the present invention, even when the weight, the muscle mass and the like of a user are changed, a large number of options for adjustable resilient characteristics are provided, and it is possible to reduce the frequency of replacement of an old cushion being used with another new cushion.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a conceptual view of a mattress 100 according to a first embodiment;

FIG. 2A is an enlarged view of a shoulder upper cushion in the first embodiment;

FIG. 2B is an enlarged view of a shoulder lower cushion in the first embodiment;

FIG. 3 is an illustrative view for the arrangement pattern of a shoulder cushion in the first embodiment;

FIG. 4 is an illustrative view for the arrangement pattern of the shoulder cushion in the first embodiment;

FIG. 5 is an illustrative view for influences exerted on the resilient characteristic of the upper surface of a cushion obtained by staking filament three-dimensional bonded members having different bulk densities in an up/down direction;

FIG. 6 is a conceptual view of a mattress 200 according to a second embodiment;

FIG. 7 is a conceptual view of a pillow 300 in a third embodiment;

FIG. 8 is a conceptual view of a pillow 400 in a fourth embodiment;

FIG. 9 is a conceptual view of a manufacturing device for a filament three-dimensional bonded member;

FIG. 10 is a cross-sectional view taken along line A-A′ shown in FIG. 9 and indicated by arrows;

FIG. 11 is an illustrative view showing an example of an external appearance when a nozzle portion is viewed from below;

FIG. 12 is an illustrative view showing another example of the external appearance when the nozzle portion is viewed from below; and

FIG. 13 is an illustrative view showing yet another example of the external appearance when the nozzle portion is viewed from below.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present invention will be described below. In the following description, an up/down direction and a forward/backward direction (orthogonal to each other) relative to a mattress and a cushion are as shown in FIG. 1 and the like. These directions are merely defined for convenience such that the thickness direction of the mattress and the cushion is the up/down direction. The cushion, the mattress and the pillow shown in FIG. 1 to FIG. 8 are shown as cross-sectional views taken along a plane orthogonal to a left/right direction (orthogonal to both the up/down direction and the forward/backward direction).

1. First Embodiment

A first embodiment of the present invention will first be described. FIG. 1 is a conceptual view of a mattress 100 according to the first embodiment. The mattress 100 is a mattress which supports a user in an upper sleeping posture. The mattress 100 is assumed to be used such that the forward/backward direction coincides with the height direction of the user, and is rectangular with the forward/backward direction being a longitudinal direction when viewed from above.

More specifically, in the mattress 100, a shoulder cushion 101 for supporting a shoulder portion, a lumbar cushion 102 for supporting a lumbar portion and a leg cushion 103 for supporting a leg portion are sequentially aligned in the forward/backward direction (the height direction of the user). If these cushions 101 to 103 are regarded as an integral cushion member, it is said that the cushion member can be divided into a plurality of cushions 101 to 103 in the height direction of the user. The mattress 100 is formed by placing these cushions 101 to 103 into a mattress cover 104. Each of the cushions 101 to 103 can be removably placed into the mattress cover 104.

The shoulder cushion 101 is formed by arranging a shoulder upper cushion 101A and a shoulder lower cushion 101B such that they overlap each other in the up/down direction, and each of the shoulder upper cushion 101A and the shoulder lower cushion 101B is formed with a filament three-dimensional bonded member. The lumbar cushion 102 is formed by arranging a lumbar upper cushion 102A and a lumbar lower cushion 102B such that they overlap each other in the up/down direction, and each of the lumbar upper cushion 102A and the lumbar lower cushion 102B is formed with the filament three-dimensional bonded member. The leg cushion 103 is formed by arranging a leg upper cushion 103A and a leg lower cushion 103B such that they overlap each other in the up/down direction, and each of the leg upper cushion 103A and the leg lower cushion 103B is formed with the filament three-dimensional bonded member. Each of the shoulder cushion 101, the lumbar cushion 102 and the leg cushion 103 can be regarded as being dividable into an upper cushion and a lower cushion in the up/down direction.

As described above, the mattress 100 is formed with the shoulder upper cushion 101A, the shoulder lower cushion 101B, the lumbar upper cushion 102A, the lumbar lower cushion 102B, the leg upper cushion 103A and the leg lower cushion 103B (in the following description, for convenience, these six cushions may be referred to as “constituent cushions Z1”). All the constituent cushions Z1 are identical in outer shape. More specifically, each of the constituent cushions Z1 is formed in the shape of a rectangular parallelepiped (in the shape of a plate the thickness of which is constant and which is rectangular when viewed from above), and the size of the rectangular parallelepiped in the up/down direction (thickness), the size of the rectangular parallelepiped in the forward/backward direction (distance between opposite sides of the rectangle) and the size of the rectangular parallelepiped in the left/right direction (distance between the other opposite sides of the rectangle) are the same in all the constituent cushions Z1. As shown in FIG. 1, the constituent cushions Z1 are placed into the mattress cover 104 to be located. Each of the constituent cushions Z1 is removed from the mattress cover 104 as necessary, is interchangeable in position with another arbitrary constituent cushion Z1 and can be installed into any position in the mattress cover 204. Since the constituent cushions Z1 are identical in outer shape, even when they are interchanged in position with each other, the original shape of the mattress 100 is maintained.

FIG. 2A is an enlarged view of the shoulder upper cushion 101A shown in FIG. 1, and FIG. 2B is an enlarged view of the shoulder lower cushion 101B shown in FIG. 1.

In the shoulder upper cushion 101A, a second resilient layer H2 is arranged on the upper side of a first resilient layer H1, and in the shoulder lower cushion 101B, a third resilient layer H3 is arranged on the upper side of a fourth resilient layer H4. The resilient layers H1 to H4 have different bulk densities. In the present embodiment, the first resilient layer H1 has the lowest bulk density, and the bulk densities of the second resilient layer H2, the third resilient layer H3 and the fourth resilient layer H4 are sequentially increased in this order.

In this way, the resilient characteristic Fa of the lower surface of the shoulder upper cushion 101A is the lowest, and resilient characteristics are sequentially enhanced in the order of the resilient characteristic Fb of the upper surface of the shoulder upper cushion 101A, the resilient characteristic Fc of the upper surface of the shoulder lower cushion 101B and the resilient characteristic Fd of the lower surface of the shoulder lower cushion 101B. In the example of the present embodiment, the resilient characteristic Fa is 80 N, the resilient characteristic Fb is 100 N, the resilient characteristic Fc is 130 N and the resilient characteristic Fd is 150 N.

Here, the “resilient characteristic” in the present application is one of the characteristics of a cushion, and is a concept which serves as an index of the magnitude of resilience generated when the cushion is compressed by a predetermined amount. It is said that as the resilient characteristic of the upper surface of the cushion is more enhanced, the upper surface of the cushion has higher resilience whereas as the resilient characteristic of the lower surface of the cushion is more enhanced, the lower surface of the cushion has higher resilience. There is a tendency that as the bulk density of the cushion formed with the filament three-dimensional bonded member is increased, the resilient characteristic is more enhanced. In the present embodiment, the value of the resilient characteristic of one (referred to as a “target surface” for convenience) of the upper surface and the lower surface of the cushion is measured with the following measurement method.

In the measurement method, a measurement cushion (the sample of the cushion to be measured) is placed on a horizontal table with the target surface directed upward, the thickness of the measurement cushion when the measurement cushion is not compressed is measured and the thickness is assumed to be L1 (mm). Then, a rod-shaped pressurizing member (loading element) in which a circular plate having a diameter of 150 mm is provided horizontally at a lower tip end is vertically brought into contact with the center portion of the target surface of the measurement cushion, and then the loading element is moved downward, with the result that the measurement cushion is gradually compressed in the thickness direction.

While the loading element is being moved as described above, as the thickness of the measurement cushion when the measurement cushion is compressed, a distance L2 (mm) between the bottom surface (the upper surface of the horizontal table) of the measurement cushion and the lower tip end of the loading element (circular plate) is measured. Then, a load which is received by the measurement cushion when the distance L2 is 7.5 mm shorter than the thickness L1 (mm) of the measurement cushion when the measurement cushion is not compressed (L2=L1−7.5) is measured as a value including the weight of the loading element, and the value (N) described above is assumed to be the resilient characteristic of the target surface of the measurement cushion. Therefore, as the resilient characteristic of the target surface of the cushion is more enhanced, even when the amount of compression is the same, resilience generated on the target surface is increased, with the result that it is said that the cushion has higher resilience on the target surface.

The resilient characteristic of the upper surface of the shoulder cushion 101 can be adjusted by changing the arrangement pattern of the constituent elements (the shoulder upper cushion 101A and the shoulder lower cushion 101B) of the shoulder cushion 101. Here, the arrangement pattern of the constituent elements of the shoulder cushion 101 will be specifically described with reference to FIGS. 3 and 4.

FIG. 3 shows variations of the arrangement pattern of the constituent elements of the shoulder cushion 101 formed with the shoulder upper cushion 101A and the shoulder lower cushion 101B. At least one of the interchange of the positions of and the reverse (reverse of upper and lower orientations) of the shoulder upper cushion 101A and the shoulder lower cushion 101B is performed, and thus a maximum of eight variations can be obtained as the arrangement pattern of the constituent elements of the shoulder cushion 101. In the variations of the arrangement pattern, the arrangement of the first to fourth resilient layers H1 to H4 in the up/down direction is different.

When as in the present embodiment, the bulk densities of the first to fourth resilient layers H1 to H4 are different from each other, in the variations, the resilient characteristics of the upper surfaces of the shoulder cushions 101 are basically different from each other. In the arrangement patterns shown in FIG. 3, the resilient characteristic of the upper surface of the shoulder cushion 101 is the lowest in the arrangement pattern (1), the resilient characteristics are sequentially enhanced in the order of the arrangement patterns (1) to (8). As described above, the resilient characteristic of the upper surface of the shoulder cushion 101 can be adjusted to a maximum of eight variations by performing at least one of the interchange of the positions of and the reverse of the shoulder upper cushion 101A and the shoulder lower cushion 101B. The reason why the arrangement of the first to fourth resilient layers H1 to H4 in the up/down direction is changed, and thus the resilient characteristic of the upper surface of the shoulder cushion 101 is changed will be described later with reference to FIG. 5.

When the constituent elements of the shoulder cushion 101 are not limited to the shoulder upper cushion 101A and the shoulder lower cushion 101B, and other cushions (all or a part of the lumbar lower cushion 102B, the leg upper cushion 103A, the lumbar upper cushion 102A and the leg lower cushion 103B) can be utilized as the constituent elements, the number of variations of the arrangement pattern of the constituent elements of the shoulder cushion 101 is further increased.

For example, when as the constituent elements of the shoulder cushion 101, the leg upper cushion 103A and the leg lower cushion 103B can be utilized, as the arrangement pattern of the constituent elements of the shoulder cushion 101, variations shown in FIG. 4 can be adopted in addition to the variations shown in FIG. 3. The variations (1) to (4) shown in FIG. 4 are examples where the shoulder upper cushion 101A and the leg upper cushion 103A are used in the configuration of the shoulder cushion 101. The variations (5) to (8) shown in FIG. 4 are examples where the shoulder lower cushion 101B and the leg lower cushion 103B are used in the configuration of the shoulder cushion 101. In the arrangement patterns shown in FIG. 4, the resilient characteristic of the upper surface of the shoulder cushion 101 is the lowest in the arrangement pattern (1), the resilient characteristics are sequentially enhanced in the order of the arrangement patterns (1) to (8).

As described above, all or a part of the lumbar lower cushion 102B, the leg upper cushion 103A, the lumbar upper cushion 102A and the leg lower cushion 103B are utilized, and thus it is possible to adjust the resilient characteristic of the upper surface of the shoulder cushion 101 to a large number of patterns.

In the present embodiment, each of the lumbar lower cushion 102B and the leg upper cushion 103A has the same configuration as the shoulder upper cushion 101A, each of the lumbar upper cushion 102A and the leg lower cushion 103B has the same configuration as the shoulder lower cushion 101B and thus the description of these configurations is omitted.

The resilient characteristic of the upper surface of the lumbar cushion 102 can be adjusted by changing the arrangement pattern of the constituent elements of the lumbar cushion 102, and the resilient characteristic of the upper surface of the leg cushion 103 can be adjusted by changing the arrangement pattern of the constituent elements of the leg cushion 103. These adjustments of the resilient characteristics are the same as the adjustment of the resilient characteristic of the upper surface of the shoulder cushion 101 described above, and thus the detailed description thereof is omitted here.

FIG. 5 schematically shows influences exerted on the resilient characteristic of the upper surface of a cushion G obtained by stacking four resilient layers L1 to LA (each of which is formed with the filament three-dimensional bonded member) in the up/down direction, for example, when a load W is applied to the upper surface. Distances d1 to d4 shown in the figure are distances from the upper surface of the cushion G. In an example shown in FIG. 5, the resilient layer L1 extends downward from the upper surface of the cushion G to the distance d1, the resilient layer L2 extends downward from the lower portion of the resilient layer L1 to the distance d2, the resilient layer L3 extends downward from the lower portion of the resilient layer L2 to the distance d3 and the resilient layer L4 extends downward from the lower portion of the resilient layer L3 to the distance d4.

In a cushion formed with a general elastic member such as a metal coil, the resilient characteristic of the upper surface of the cushion (a load necessary for compressing the cushion by a predetermined amount) is constant even when the orientation of the elastic member in the up/down direction is changed or even when the elastic member is formed with a plurality of layers and the arrangement of the layers in the up/down direction is changed. On the other hand, the resilient characteristic of the upper surface of the cushion G formed with the resilient layers L1 to L4 is significantly changed not only by the influence of a force (vertical compression force T1) in the up/down direction generated in the cushion G when the load W is applied but also by the influence of a force (horizontal tension T2) in a horizontal direction, that is, is changed by both the influences of the vertical compression force T1 and the horizontal tension T2.

Consequently, regarding the influences exerted on the resilient characteristic of the upper surface of the cushion G which are obtained as a reaction of the load W, the influence caused by the bulk density of the resilient layer L1 is the greatest, and the influences are sequentially decreased in the order of the influence caused by the bulk density of the resilient layer L1, the influence caused by the bulk density of the resilient layer L2, the influence caused by the bulk density of the resilient layer L3 and the influence caused by the bulk density of the resilient layer L4.

As described above, in the case of the cushion where a plurality of resilient layers (filament three-dimensional bonded members) having different bulk densities are arranged in the up/down direction, depending on in which positions in the up/down direction the resilient layers are arranged, the resilient characteristic of the upper surface of the cushion is changed. Hence, the arrangement of the first to fourth resilient layers H1 to H4 of the shoulder cushion 101 in the up/down direction is changed, and thus the resilient characteristic of the upper surface of the shoulder cushion 101 is changed.

The cushion according to the present invention utilizes the characteristics of the filament three-dimensional bonded member as described above to successfully increase the degree of freedom of the adjustment of the resilient characteristic, and achieves a special effect which is not available with the cushion formed with the general elastic member such as a metal coil. The influence of the horizontal tension T2 described above is remarkable on the high resilient filament three-dimensional bonded member the resilient characteristic of which exceeds 80 N. In particular, when the resilient characteristic exceeds 120 N, the horizontal tension T2 has a significantly large influence on a local compression which occurs when a knee or an elbow is placed on the cushion, and thus it is possible to effectively reduce the feelings of sinking and hitting the bottom without excessively enhancing the resilient characteristic.

2. Second Embodiment

A second embodiment of the present invention will then be described. In the following description, configurations different from those in the first embodiment will be mainly described, and the same configurations as in the first embodiment may be omitted.

FIG. 6 is a conceptual view of a mattress 200 according to the second embodiment. The mattress 200 is a mattress which supports the user in the upper sleeping posture. The mattress 200 is assumed to be used such that the forward/backward direction coincides with the height direction of the user, and is rectangular with the forward/backward direction being the longitudinal direction when viewed from above.

More specifically, in the mattress 200, a shoulder cushion 201 for supporting the shoulder portion, a lumbar cushion 202 for supporting the lumbar portion and a leg cushion 203 for supporting the leg portion are sequentially aligned in the forward/backward direction (the height direction of the user). If these cushions 201 to 203 are regarded as an integral cushion member, it is said that the cushion member can be divided into a plurality of cushions 201 to 203 in the height direction of the user. The mattress 200 is formed by placing these cushions 201 to 203 into a mattress cover 204. Each of the cushions 201 to 203 can be removably placed into the mattress cover 204.

The shoulder cushion 201 is formed by arranging a shoulder first cushion 201A, a shoulder second cushion 201B, a shoulder third cushion 201C and a shoulder fourth cushion 201D such that they overlap each other in the up/down direction, and each of the shoulder first cushion 201A, the shoulder second cushion 201B, the shoulder third cushion 201C and the shoulder fourth cushion 201D is formed with the filament three-dimensional bonded member. The lumbar cushion 202 is formed by arranging a lumbar first cushion 202A, a lumbar second cushion 202B, a lumbar third cushion 202C and a lumbar fourth cushion 202D such that they overlap each other in the up/down direction, and each of the lumbar first cushion 202A, the lumbar second cushion 202B, the lumbar third cushion 202C and the lumbar fourth cushion 202D is formed with the filament three-dimensional bonded member.

The leg cushion 203 is formed by arranging a leg first cushion 203A, a leg second cushion 203B, a leg third cushion 203C and a leg fourth cushion 203D such that they overlap each other in the up/down direction, and each of the leg first cushion 203A, the leg second cushion 203B, the leg third cushion 203C and the leg third cushion 204C is formed with the filament three-dimensional bonded member. Each of the shoulder cushion 201, the lumbar cushion 1202 and the leg cushion 203 can be regarded as being dividable into the first to fourth cushions in the up/down direction.

As described above, the mattress 200 is formed with the four cushions 201A to 201D of the shoulder cushion, the four cushions 202A to 202D of the lumbar cushion and the four cushions 203A to 203D of the leg cushion (in the following description, for convenience, the total of these twelve cushions may be referred to as “constituent cushions Z2”).

All the constituent cushions Z2 are identical in outer shape. More specifically, each of the constituent cushions Z2 is formed in the shape of a rectangular parallelepiped (in the shape of a plate the thickness of which is constant and which is rectangular when viewed from above), and the size of the rectangular parallelepiped in the up/down direction (thickness), the size of the rectangular parallelepiped in the forward/backward direction (distance between opposite sides of the rectangle) and the size of the rectangular parallelepiped in the left/right direction (distance between the other opposite sides of the rectangle) are the same in all the constituent cushions Z2. As shown in FIG. 6, the constituent cushions Z2 are placed into the mattress cover 204 to be located. Each of the constituent cushions Z2 is removed from the mattress cover 204 as necessary, is interchangeable in position with another arbitrary constituent cushion Z2 and can be installed into any position in the mattress cover 204. Since the constituent cushions Z2 are identical in outer shape, even when they are interchanged in position with each other, the original shape of the mattress 200 is maintained.

Each of the shoulder first cushion 201A, the lumbar fourth cushion 202D and the leg third cushion 203C is entirely formed with the first resilient layer H1, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface. Each of the shoulder second cushion 201B, the lumbar third cushion 202C and the leg first cushion 203A is entirely formed with the second resilient layer H2, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface.

Each of the shoulder fourth cushion 201D, the lumbar first cushion 202A and the leg fourth cushion 203D is entirely formed with the third resilient layer H3, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface. Each of the shoulder third cushion 201C, the lumbar second cushion 202B and the leg second cushion 203B is entirely formed with the fourth resilient layer H4, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface.

In the present embodiment, the resilient layers H1 to H4 have different bulk densities. In the present embodiment, the first resilient layer H1 has the lowest bulk density, and the bulk densities of the second resilient layer H2, the third resilient layer H3 and the fourth resilient layer H4 are sequentially increased in this order. In this way, the resilient characteristic Fa of the upper surface and the lower surface of the cushion formed with the first resilient layer H1 is the lowest, and resilient characteristics are sequentially enhanced in the order of the resilient characteristic Fb of the upper surface and the lower surface of the cushion formed with the second resilient layer H2, the resilient characteristic Fc of the upper surface and the lower surface of the cushion formed with the third resilient layer H3 and the resilient characteristic Fd of the upper surface and the lower surface of the cushion formed with the fourth resilient layer H4. In the example of the present embodiment, the resilient characteristic Fa is 80 N, the resilient characteristic Fb is 100 N, the resilient characteristic Fc is 130 N and the resilient characteristic Fd is 150 N.

In the present embodiment, as the arrangement pattern of the constituent cushions Z2 (that is, the shoulder first to fourth cushions 201A to 201D) of the shoulder cushion 201, 24 arrangement patterns are provided. In this way, a maximum of 24 options are available for the resilient characteristic of the upper surface of the shoulder cushion 201, and a very high degree of freedom of the adjustment of the resilient characteristic is provided. Likewise, for each of the lumbar cushion 202 and the leg cushion 203, a maximum of 24 options are available for the resilient characteristic of the upper surface, and a very high degree of freedom of the adjustment of the resilient characteristic is provided. All the arrangements of the total of twelve constituent cushions Z2 are freely changed, and thus the degree of freedom of the adjustment of the resilient characteristic is further increased.

Although in the second embodiment, each of the shoulder cushion 201, the lumbar cushion 202 and the leg cushion 203 is formed with the four constituent cushions Z2, in a variation, each of the shoulder cushion 201, the lumbar cushion 202 and the leg cushion 203 may be formed with three or five or more constituent cushions Z2. When in an example, each of the shoulder cushion 201, the lumbar cushion 202 and the leg cushion 203 is formed with three constituent cushions Z3, for each of the shoulder cushion 201, the lumbar cushion 202 and the leg cushion 203, six arrangement patterns of the constituent cushions Z2 are provided, and a maximum of six options are available for the resilient characteristic of the upper surface.

3. Third Embodiment

A third embodiment of the present invention will then be described. In the following description, configurations different from those in the first embodiment will be mainly described, and the same configurations as in the first embodiment may be omitted.

FIG. 7 is a conceptual view of a pillow 300 in the third embodiment. The pillow 300 can be utilized to support the head of the user in the upper sleeping posture. The pillow 300 is formed by placing a pillow cushion 301 into a pillow cover 302. The pillow cushion 301 is formed with a pillow upper cushion 301A and a pillow lower cushion 301B such that they overlap each other in the up/down direction, and each of the pillow upper cushion 301A and the pillow lower cushion 301B is formed with the filament three-dimensional bonded member (in the following description, for convenience, these two cushions may be referred to as “constituent cushions Z3”). The pillow cushion 301 can be regarded as being dividable into the constituent cushions Z3 in the up/down direction. The constituent cushions Z3 can be removably placed into the pillow cover 302.

All the constituent cushions Z3 are identical in outer shape. More specifically, each of the constituent cushions Z3 is formed in the shape of a rectangular parallelepiped (in the shape of a plate the thickness of which is constant and which is rectangular when viewed from above), and the size of the rectangular parallelepiped in the up/down direction (thickness), the size of the rectangular parallelepiped in the forward/backward direction (distance between opposite sides of the rectangle) and the size of the rectangular parallelepiped in the left/right direction (distance between the other opposite sides of the rectangle) are the same in all the constituent cushions Z3.As shown in FIG. 7, the constituent cushions Z3 are placed into the pillow cover 302 to be located. Each of the constituent cushions Z3 is removed from the pillow cover 302 as necessary, is interchangeable in position with another constituent cushion Z3 and can be installed into any position in the pillow cover 302. Since the constituent cushions Z3 are identical in outer shape, even when they are interchanged in position with each other, the original shape of the pillow 300 is maintained.

In the pillow upper cushion 301A, a second resilient layer S2 is arranged on the upper side of a first resilient layer S1, and in the pillow lower cushion 301B, a third resilient layer S3 is arranged on the upper side of a fourth resilient layer S4. The resilient layers S1 to S4 have different bulk densities. In the present embodiment, the first resilient layer S1 has the lowest bulk density, and the bulk densities of the second resilient layer S2, the third resilient layer S3 and the fourth resilient layer S4 are sequentially increased in this order. In this way, the resilient characteristic Fp of the lower surface of the pillow upper cushion 301A is the lowest, and resilient characteristics are sequentially enhanced in the order of the resilient characteristic Fq of the upper surface of the pillow upper cushion 301A, the resilient characteristic Fr of the upper surface of the pillow lower cushion 301B and the resilient characteristic Fs of the lower surface of the pillow upper cushion 301A. In the example of the present embodiment, the resilient characteristic Fp is 10 N, the resilient characteristic Fq is 20 N, the resilient characteristic Fr is 30 N and the resilient characteristic Fs is 40 N.

As in the shoulder cushion 101 and the like in the first embodiment, the resilient characteristic of the upper surface of the pillow cushion 301 can be adjusted by changing the arrangement pattern of the pillow cushion 301. Specifically, at least one of the interchange of the positions of and the reverse of the pillow upper cushion 301A and the pillow lower cushion 301B is performed, and thus a maximum of eight variations can be obtained as the arrangement pattern of the pillow cushion 301. In the variations of the arrangement pattern, the arrangement of the first to fourth resilient layers S1 to S4 in the up/down direction is different.

When as in the present embodiment, the resilient characteristics of the first to fourth resilient layers S1 to S4 are different from each other, in the variations, the resilient characteristics of the upper surfaces of the pillow cushions 301 are basically different from each other. As described above, the resilient characteristic of the upper surface of the pillow cushion 301 can be adjusted to a maximum of eight variations by performing at least one of the interchange of the positions of and the reverse of the pillow upper cushion 301A and the pillow lower cushion 301B.

4. Fourth Embodiment

A fourth embodiment of the present invention will then be described. In the following description, configurations different from those in the third embodiment will be mainly described, and the same configurations as in the third embodiment may be omitted.

FIG. 8 is a conceptual view of a pillow 400 in the fourth embodiment. The pillow 400 can be utilized to support the head of the user in the upper sleeping posture. The pillow 400 is formed by placing a pillow cushion 401 into a pillow cover 402. The pillow cushion 401 is formed with a pillow first cushion 401A, a pillow second cushion 401B, a pillow third cushion 401C and a pillow fourth cushion 401D such that they overlap each other in the up/down direction, and each of the pillow first cushion 401A, the pillow second cushion 401B, the pillow third cushion 401C and the pillow fourth cushion 401D is formed with the filament three-dimensional bonded member (in the following description, for convenience, the total of four cushions may be referred to as “constituent cushions Z4”). The pillow cushion 401 can be regarded as being dividable into the constituent cushions Z4 in the up/down direction. The constituent cushions Z4 can be removably placed into the pillow cover 402.

All the constituent cushions Z4 are identical in outer shape. More specifically, each of the constituent cushions Z4 is formed in the shape of a rectangular parallelepiped (in the shape of a plate the thickness of which is constant and which is rectangular when viewed from above), and the size of the rectangular parallelepiped in the up/down direction (thickness), the size of the rectangular parallelepiped in the forward/backward direction (distance between opposite sides of the rectangle) and the size of the rectangular parallelepiped in the left/right direction (distance between the other opposite sides of the rectangle) are the same in all the constituent cushions Z4. As shown in FIG. 8, the constituent cushions Z4 are placed into the pillow cover 402 to be located. Each of the constituent cushions Z4 is removed from the pillow cover 402 as necessary, is interchangeable in position with another constituent cushion Z4 and can be installed into any position in the pillow cover 402. Since the constituent cushions Z4 are identical in outer shape, even when they are interchanged in position with each other, the original shape of the pillow 400 is maintained.

The pillow first cushion 401 is entirely formed with the first resilient layer S1, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface. The pillow second cushion 402 is entirely formed with the fourth resilient layer S4, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface. The pillow third cushion 403 is entirely formed with the third resilient layer S3, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface. The pillow fourth cushion 404 is entirely formed with the second resilient layer S2, and thus the resilient characteristic of the upper surface is the same as the resilient characteristic of the lower surface.

In the present embodiment, the resilient layers S1 to S4 have different bulk densities. In the present embodiment, the first resilient layer S1 has the lowest bulk density, and the bulk densities of the second resilient layer S2, the third resilient layer S3 and the fourth resilient layer S4 are sequentially increased in this order. In this way, the resilient characteristic Fp of the upper surface and the lower surface of the pillow first cushion 401 formed with the first resilient layer S1 is the lowest, and resilient characteristics are sequentially enhanced in the order of the resilient characteristic Fq of the upper surface and the lower surface of the pillow fourth cushion 404 formed with the second resilient layer S2, the resilient characteristic Fr of the upper surface and the lower surface of the pillow third cushion 403 formed with the third resilient layer S3 and the resilient characteristic Fs of the upper surface and the lower surface of the pillow second cushion 402 formed with the fourth resilient layer S4. In the example of the present embodiment, the resilient characteristic Fp is 10 N, the resilient characteristic Fq is 20 N, the resilient characteristic Fr is 30 N and the resilient characteristic Fs is 40 N.

As in the shoulder cushion 201 and the like in the second embodiment, the resilient characteristic of the upper surface of the pillow cushion 401 can be adjusted by changing the arrangement pattern of the constituent cushions Z4. Specifically, the interchange of the positions of the constituent cushions 401A to 401D is performed, and thus a maximum of 24 variations can be obtained as the arrangement pattern of the pillow cushion 401. In the variations of the arrangement pattern, the arrangement of the first to fourth resilient layers S1 to S4 in the up/down direction is different.

When as in the present embodiment, the resilient characteristics of the first to fourth resilient layers S1 to S4 are different from each other, in the variations, the resilient characteristics of the upper surfaces of the pillow cushions 401 are basically different from each other. As described above, the resilient characteristic of the upper surface of the pillow cushion 401 can be adjusted to a maximum of 24 variations by performing the interchange of the positions of the constituent cushions 401A to 401D.

5. Manufacturing device for filament three-dimensional bonded member

An example of a manufacturing device for the filament three-dimensional bonded member which can manufacture the constituent cushions Z1 to Z4 in the embodiments described above will then be described.

FIG. 9 is a conceptual view of the manufacturing device 1 for the filament three-dimensional bonded member. FIG. 10 is a cross-sectional view taken along line A-A′ shown in FIG. 9 and indicated by arrows. Directions (directions orthogonal to each other) which are an up/down direction, a left/right direction and a forward/backward direction relative to the manufacturing device 1 are as shown in the figures. These directions are merely defined for convenience such that a vertical direction is the up/down direction, and a direction in which a pair of seamless conveyors 26 and 27 to be described later are opposite each other is the forward/backward direction.

The manufacturing device 1 for the filament three-dimensional bonded member includes: a molten filament supply unit 10 which discharges, downward in the vertical direction, a molten filament group MF formed with a plurality of molten filaments having a diameter of 0.5 mm to 3 mm; and a fusing formation unit 20 which three-dimensionally entangles the molten filament group MF, simultaneously fuses contact points and thereafter cools and solidifies the molten filament group MF to form the filament three-dimensional bonded member.

The molten filament supply unit 10 includes a pressurization melting portion 11 (extruder) and a filament discharge portion 12 (die). The pressurization melting portion 11 includes a material input portion 13 (hopper), a screw 14, a screw motor 15 for driving the screw 14, a screw heater 16 and a plurality of unillustrated temperature sensors. Within the pressurization melting portion 11, a cylinder 11a is formed which conveys a thermoplastic resin supplied from the material input portion 13 while heating and melting the thermoplastic resin with the screw heater 16.

Within the cylinder 11a, the screw 14 is rotatably stored. At an end portion of the cylinder 11a on a downstream side, a cylinder discharge port 11b for discharging the thermoplastic resin toward the filament discharge portion 12 is formed. A heating temperature for the screw heater 16 is controlled based on, for example, the detection signal of a temperature sensor provided in the molten filament supply unit 10.

The filament discharge portion 12 includes a nozzle portion 17, die heaters 18 and a plurality of unillustrated temperature sensors, and within the filament discharge portion 12, a guide flow path 12a is formed which guides, to the nozzle portion 17, the molten thermoplastic resin discharged from the cylinder discharge port 11b.

The nozzle portion 17 is a thick plate in which a plurality of openings are formed, and which is formed substantially in the shape of a rectangular parallelepiped, is made of metal and is provided in a lower portion of the filament discharge portion 12 that is the most downstream portion of the guide flow path 12a. In the nozzle portion 17, a plurality of nozzle holes for discharging the molten filament group are formed.

A plurality of (six in an example shown in FIG. 10) die heaters 18 are provided in the left/right direction, and heats the filament discharge portion 12. The heating temperature of the die heaters 18 is controlled based on the detection signal of a temperature sensor provided, for example, in the filament discharge portion 12.

Examples of the thermoplastic resin which can be used as the material of the filament three-dimensional bonded member include: polyolefin resins such as polyethylene and polypropylene; polyester resins such as polyethylene terephthalate; polyamide resins such as nylon 66; a polyolefin elastomer; a polyester elastomer; a polyurethane elastomer; a polyamide elastomer; an amorphous polystyrene elastomer; a crystalline polystyrene elastomer; and the like.

The thermoplastic resin supplied from the material input portion 13 is heated and melted within the cylinder 11a and is, for example, supplied as the molten thermoplastic resin from the cylinder discharge port 11b to the guide flow path 12a of the filament discharge portion 12 so as to be extruded by the screw 14. Thereafter, the molten filament group MF formed with a plurality of molten filaments is discharged downward in parallel from the nozzle in the nozzle portion 17.

The fusing formation unit 20 includes a cooling water tank 21, a pair of seamless conveyors 26 and 27, a plurality of conveyance rollers 28 to 35, a pair of chutes 22 and 23 and cooling water supply portions 24 and 25 which supply cooling water to upper portions of the chutes 22 and 23, respectively.

The cooling water tank 21 is a water tank for storing the cooling water W. Within the cooling water tank 21, the pair of seamless conveyors 26 and 27 and the conveyance rollers 28 to 35 are provided. The pair of seamless conveyors 26 and 27 and the conveyance rollers 28 to 35 are driven by an unillustrated drive motor.

The pair of chutes 22 and 23 receive the molten filaments at end portions (both left and right end portions in the forward/backward direction) int the thickness direction of the molten filament group MF, and moves them in such a direction as to reduce the thickness of the molten filament group MF. Although in the present embodiment, each of the chutes 22 and 23 is formed in the shape of a bent flat plate, each of the chutes 22 and 23 may be curved or may be integrated to form a square or oval space.

In the fusing formation unit 20, the molten filament group MF is adjusted in thickness (dimension in the forward/backward direction) by the pair of chutes 22 and 23, and is deformed by the buoyant action of the cooling water W in the cooling water tank 21, and thus the molten filaments form random loops. The random loop is three-dimensionally entangled with the adjacent random loops in a molten state, simultaneously, contact points are fused and the filament three-dimensional bonded member 3DF (three-dimensional bonded member of filaments) is formed. The filament three-dimensional bonded member 3DF is further cooled by the cooling water W with its thickness kept constant while being conveyed between the seamless conveyors 26 and 27, and is solidified.

Furthermore, the filament three-dimensional bonded member 3DF is conveyed by the conveyance rollers 28 to 35 while being cooled by the cooling water W in the cooling water tank 21, and is fed out of the cooling water tank 21. The filament three-dimensional bonded member 3DF fed out of the cooling water tank 21 is cut to appropriate sizes, and can be utilized as the constituent cushions Z1 to Z4 in the embodiments.

Here, the bulk density of the filament three-dimensional bonded member 3DF which determines the resilient characteristic of the cushion can be adjusted by changing the form and like of the nozzle holes in the nozzle portion 17 described previously. For example, the inside diameter (nozzle diameter) of the nozzle holes is increased or the distance (nozzle distance) between adjacent nozzle holes is decreased, and the bulk density of the filament three-dimensional bonded member 3DF to be manufactured is increased accordingly, with the result that the cushion having a high resilient characteristic is obtained.

In order to obtain a constituent cushion the entire bulk density of which is substantially uniform such as the constituent cushion Z2 in the second embodiment or the constituent cushion Z4 in the fourth embodiment, it is basically preferable to cause the nozzle diameter, the nozzle distance or the like in the nozzle portion 17 to be uniform. On the other hand, in order to obtain a constituent cushion which has different bulk densities in a part close to the upper side and in a part close to the lower side, it is preferable to partially change the nozzle diameter, the nozzle distance or the like in the nozzle portion 17.

FIG. 11 shows an example of a schematic external appearance of the nozzle portion 17 when the nozzle portion 17 is viewed from below. In the nozzle portion 17 shown in FIG. 11, all the nozzle holes are circular when viewed from below, and the nozzle diameter and the nozzle distance are constat. Hence, the manufacturing device 1 which includes the nozzle portion 17 illustrated in FIG. 11 is suitable for manufacturing the constituent cushion the entire bulk density of which is substantially uniform.

FIG. 12 shows another example of the external appearance of the nozzle portion 17 when the nozzle portion 17 is viewed from below. In the nozzle portion 17 shown in FIG. 12, the nozzle diameter is constant but nozzle holes 17a provided in a part close to the front side (inside a dashed frame α shown in FIG. 12) and nozzle holes 17a provided in a part close to the back side (inside a dashed frame β shown in FIG. 12) have different nozzle distances. As the nozzle distance is decreased, the amount of molten filament discharged per unit area in the corresponding part is increased, and thus the bulk density of the filament three-dimensional bonded member 3DF corresponding to the part is increased.

Hence, the manufacturing device 1 which includes the nozzle portion 17 illustrated in FIG. 12 is suitable for manufacturing the cushion in which the part close to the upper side and the part close to the lower side have different bulk densities. In other words, of the part close to the upper side and the part close to the lower side in the cushion, the part having a higher bulk density is formed with molten filaments discharged from the nozzle holes 17a inside the dashed frame α, and the part having a lower bulk density is formed with molten filaments discharged from the nozzle holes 17a inside the dashed frame β, and thus it is possible to easily manufacture the cushion described above. The filament three-dimensional bonded member 3DF manufactured with the manufacturing device 1 which includes the nozzle portion 17 illustrated in FIG. 12 is cut into the part formed with molten filaments discharged from the nozzle holes 17a inside the dashed frame α and the part formed with molten filaments discharged from the nozzle holes 17a inside the dashed frame β, with the result that these parts may be utilized as the constituent cushion Z2 in the second embodiment and the constituent cushion Z4 in the fourth embodiment.

Although in an example shown in FIG. 12, all the nozzle holes are circular when viewed from below and have a nozzle diameter of 1.2 mm, the nozzle holes 17a provided inside the dashed frame α have a nozzle distance of 10 mm, and the nozzle holes 17a provided inside the dashed frame α have a nozzle distance of 15 mm. FIG. 13 shows yet another example of the external appearance of the nozzle portion 17 when the nozzle portion 17 is viewed from below. Although in the nozzle portion 17 shown in FIG. 13, all the nozzle holes are circular when viewed from below and have a nozzle diameter of 0.8 mm, the nozzle holes 17a provided inside the dashed frame α and the nozzle holes 17a provided inside the dashed frame β have different nozzle distances. In an example shown in FIG. 13, the nozzle holes 17a provided inside the dashed frame α have a nozzle distance of 10 mm, and the nozzle holes 17a provided inside the dashed frame β have a nozzle distance of 15 mm.

In the nozzle holes 17a in the nozzle portion 17, the cross-sectional shape, the nozzle diameter, the nozzle distance, the arrangement or the like thereof can be adjusted as necessary such that the filament three-dimensional bonded member having a desired bulk density can be manufactured.

6. Others

In the shoulder cushion 101 according to the first embodiment described previously, each of the shoulder upper cushion 101A (upper cushion) and the shoulder lower cushion 101B (lower cushion) is formed with the filament three-dimensional bonded member, the shoulder upper cushion 101A and the shoulder lower cushion 101B are arranged to overlap each other in the up/down direction and the shoulder upper cushion 101A and the shoulder lower cushion 101B are interchangeable in position, and are reversible in vertical orientation. Furthermore, in the shoulder cushion 101, at least three of the resilient characteristic Fb of the upper surface of the shoulder upper cushion 101A, the resilient characteristic Fa of the lower surface of the shoulder upper cushion 101A, the resilient characteristic Fc of the upper surface of the shoulder lower cushion 101B and the resilient characteristic Fd of the lower surface of the shoulder lower cushion 101B (the total of four resilient characteristics) are different from each other.

In the shoulder cushion 101 which has such a feature (referred to as a “first feature” for convenience), the upper cushion and the lower cushion in which the upper surface and the lower surface have different resilient characteristics are interchanged, the upper cushion and the lower cushion are individually reversed and thus eight arrangement patterns can be obtained in the arrangement of the upper cushion and the lower cushion. Hence, a maximum of eight options are available for the resilient characteristic of the upper surface of the shoulder cushion 101, and thus the shoulder cushion 101 has a large number of options when the resilient characteristic is adjusted. Even when the weight, the muscle mass and the like of the user are changed, the shoulder cushion 101 as described above has a large number of options for the adjustable resilient characteristic, and thus it is possible to reduce the frequency of replacement of an old cushion being used with another new cushion. Each of the lumbar cushion 102 and the leg cushion 103 in the first embodiment and the pillow cushion 301 in the third embodiment has the same feature as the first feature.

The mattress 100 according to the first embodiment that supports the user in the upper sleeping posture includes a plurality of cushions X that are aligned in the height direction of the user. At least one of the plurality of cushions X are specific cushions each having the first feature or a feature equivalent thereto.

Hence, for the mattress 100, in the specific cushion which is at least one of the cushions for supporting predetermined parts (such as a shoulder portion, a lumbar portion and a leg portion) of the user, the upper cushion and the lower cushion in which the upper surface and the lower surface have different resilient characteristics are interchanged, the upper cushion and the lower cushion are individually reversed and thus eight arrangement patterns can be obtained in the arrangement of the upper cushion and the lower cushion. Therefore, the resilient characteristic of the upper surface of the specific cushion can be changed to a maximum of eight options, and thus it is possible to obtain the mattress which has a large number of options when the resilient characteristic is adjusted. Consequently, even when the body shape of the user such as the weight and the muscle mass is changed, the resilient characteristic is easily adjusted according to the body shape of the user.

The plurality of cushions X include, as the specific cushion, the shoulder cushion 101 for supporting the shoulder portion, the lumbar cushion 102 for supporting the lumbar portion and the leg cushion 103 for supporting the leg portion, and all the upper cushions (that is, the shoulder upper cushion 101A, the lumbar upper cushion 102A and the leg upper cushion 103A) and the lower cushions (that is, the shoulder lower cushion 101B, the lumbar lower cushion 102B and the leg lower cushion 103B) of the cushions 101 to 103 are identical in outer shape.

Hence, in the mattress 100, the shoulder upper cushion 101A, the shoulder lower cushion 101B, the lumbar upper cushion 102A, the lumbar lower cushion 102B, the leg upper cushion 103A and the leg lower cushion 103B are interchanged, and are individually reversed and thus in each of the shoulder cushion 101, the lumbar cushion 102 and the leg cushion 103, eight arrangement patterns can be obtained in the arrangement of the upper cushion and the lower cushion. Therefore, the resilient characteristic of the upper surface of each of the shoulder cushion 101, the lumbar cushion 102 and the leg cushion 103 can be changed to a maximum of eight options, and thus it is possible to obtain the mattress which has a large number of options when the resilient characteristic is adjusted.

Furthermore, all the shoulder upper cushion 101A, the shoulder lower cushion 101B, the lumbar upper cushion 102A, the lumbar lower cushion 102B, the leg upper cushion 103A and the leg lower cushion 103B are identical in outer shape, and thus it is possible to interchange the upper cushion and the lower cushion in each of the shoulder cushion 101, the lumbar cushion 102 and the leg cushion 103. Consequently, in the shoulder cushion 101, the lumbar cushion 102 and the leg cushion 103, an extremely large number of (for example, 16) arrangement patterns of the upper cushion and the lower cushion can be obtained, and thus it is possible to increase the number of options when the resilient characteristic of the upper surface of each of the shoulder cushion 101, the lumbar cushion 102 and the leg cushion 103 is adjusted.

The shoulder cushion 201 according to the second embodiment describe previously includes a predetermined number of (in the example of the second embodiment, four) constituent cushions Z2, the predetermined number is three or more, each of the predetermined number of constituent cushions Z2 is formed with the filament three-dimensional bonded member such that resilient characteristics of the upper surface and the lower surface are equivalent, the predetermined number of constituent cushions Z2 are arranged to overlap each other in the up/down direction, the resilient characteristics of the upper surfaces of the predetermined number of constituent cushions Z2 are different from each other, all the predetermined number of constituent cushions Z2 are identical in outer shape and the constituent cushions Z2 are interchangeable in position.

In the shoulder cushion 201 which has such a feature (referred to as a “second feature” for convenience), at least six options can be obtained as the arrangement pattern of the constituent cushions Z2, and thus the degree of freedom of the adjustment of the resilient characteristic can be increased. Since all the predetermined number of constituent cushions Z2are identical in outer shape, the predetermined number of constituent cushions Z2 are interchangeable in position without the entire outer shape of the shoulder cushion 201 being changed. Each of the lumbar cushion 202 and the leg cushion 203 in the second embodiment and the pillow cushion 401 in the fourth embodiment has a feature equivalent to the second feature.

The mattress 200 according to the second embodiment described previously that supports the user in the upper sleeping posture includes a plurality of cushions that are aligned in the height direction of the user, and at least one of the plurality of cushions are a cushion having the second feature or a feature equivalent thereto. Hence, the mattress 200 can support parts (such as the shoulder portion, the lumbar portion and the leg portion) the positions of which are different from each other in the height direction of the user, and it is possible to increase the degree of freedom of the adjustment of the resilient characteristic for the cushions corresponding to the parts. Consequently, even when the body shape of the user such as the weight and the muscle mass is changed, the resilient characteristic is easily adjusted according to the body shape of the user.

The mattress 200 according to the second embodiment described previously that supports the user in the upper sleeping posture includes a plurality of cushions that are aligned in the height direction of the user, and the plurality of cushions include the shoulder cushion 201 for supporting the shoulder portion, the lumbar cushion 202 for supporting the lumbar portion and the leg cushion 203 for supporting the leg portion.

Furthermore, the shoulder cushion 201 includes a predetermined number of (in the example of the second embodiment, four) shoulder constituent cushions (the shoulder first to fourth cushions 201A to 201D), the predetermined number is three or more, each of the predetermined number of constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics of the upper surface and the lower surface are equivalent and the predetermined number of constituent cushions are arranged to overlap each other in the up/down direction. The lumbar cushion 202 includes the predetermined number of lumbar constituent cushions (the lumbar first to fourth cushions 202A to 202D), each of the predetermined number of lumbar constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics of the upper surface and the lower surface are equivalent and the predetermined number of lumbar constituent cushions are arranged to overlap each other in the up/down direction. The leg cushion 203 includes the predetermined number of leg constituent cushions (the leg first to fourth cushions 203A to 203D), each of the predetermined number of leg constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics of the upper surface and the lower surface are equivalent and the predetermined number of leg constituent cushions are arranged to overlap each other in the up/down direction. The resilient characteristics of the upper surfaces of the shoulder constituent cushions 201A to 201D are different from each other, and the shoulder constituent cushions 201A to 201D are identical in outer shape, the resilient characteristics of the upper surfaces of the lumbar constituent cushions 202A to 202D are different from each other, and the lumbar constituent cushions 202A to 202D are identical in outer shape and the resilient characteristics of the upper surfaces of the leg constituent cushions 203A to 203D are different from each other, and the leg constituent cushions 203A to 203D are identical in outer shape.

Hence, in the mattress 200, without changing the entire outer shape thereof, it is possible to freely change the arrangement of the constituent cushions Z2 in each of the cushions 201 to 203 which support the shoulder portion, the lumbar portion and the leg portion of the user. Consequently, the degree of freedom of the adjustment of the resilient characteristics of the cushions which support the shoulder portion, the lumbar portion and the leg portion of the user is extremely increased.

According to the present invention, a large number of arrangement patterns of the constituent cushions of the cushion are provided, and thus the number of options (the degree of freedom of the adjustment) when the resilient characteristic of the cushion is adjusted is increased, with the result that it is possible to reduce the frequency of replacement of a cushion being used with another new cushion. Consequently, it is possible to reduce the frequency of replacement of an old cushion being used with another new cushion and of discarding of the old cushion.

It should be considered that the embodiments described above are illustrative in all respects, and not restrictive. The technical scope of the present invention is indicated not by the description of the embodiments but by the scope of claims, and meanings equivalent to the scope of claims and all changes in the scope should be understood to be included. The cushion according to the present invention can be utilized not only for a mattress, a pillow, a chair and the like but also for various items including a cushion.

INDUSTRIAL APPLICABILITY

The present invention can be utilized, for example, for cushions which can be used in a mattress, a pillow a chair and the like.

REFERENCE SIGNS LIST

    • 1 manufacturing device for filament three-dimensional bonded member
    • 10 molten filament supply unit
    • 11 pressurization melting portion
    • 11a cylinder
    • 11b cylinder discharge port
    • 12 filament discharge portion
    • 12a guide flow path
    • 13 material input portion
    • 14 screw
    • 15 screw motor
    • 16 screw heater
    • 17 nozzle portion
    • 17a nozzle hole
    • 18 die heater
    • 20 fusing formation unit
    • 21 cooling water tank
    • 22, 23 chute
    • 24, 25 cooling water supply portion
    • 26, 27 seamless conveyor
    • 28 to 35 conveyance roller
    • 100, 200 mattress
    • 101, 201 shoulder cushion
    • 102, 202 lumbar cushion
    • 103, 203 leg cushion
    • 101A shoulder upper cushion
    • 101B shoulder lower cushion
    • 102A lumbar upper cushion
    • 102B lumbar lower cushion
    • 103A leg upper cushion
    • 103B leg lower cushion
    • 104, 204 mattress cover
    • 201A shoulder first cushion
    • 201B shoulder second cushion
    • 201C shoulder third cushion
    • 201D shoulder fourth cushion
    • 202A lumbar first cushion
    • 202B lumbar second cushion
    • 202C lumbar third cushion
    • 202D lumbar fourth cushion
    • 203A leg first cushion
    • 203B leg second cushion
    • 203C leg third cushion
    • 203D leg fourth cushion
    • 300, 400 pillow
    • 301, 401 pillow cushion
    • 301A pillow upper cushion
    • 301B pillow lower cushion
    • 302, 402 pillow cover
    • 401A pillow first cushion
    • 401B pillow second cushion
    • 401C pillow third cushion
    • 401D pillow fourth cushion

Claims

1. A cushion, comprising:

an upper cushion; and
a lower cushion,
wherein each of the upper cushion and the lower cushion is formed with a filament three-dimensional bonded member, and the upper cushion and the lower cushion are arranged to overlap each other in an up/down direction,
the upper cushion and the lower cushion are interchangeable in position, and are reversible in vertical orientation, and
at least three of a resilient characteristic of an upper surface of the upper cushion, a resilient characteristic of a lower surface of the upper cushion, a resilient characteristic of an upper surface of the lower cushion and a resilient characteristic of a lower surface of the lower cushion are different from each other.

2. A mattress that supports a user in an upper sleeping posture, the mattress comprising:

a plurality of cushions that are aligned in a height direction of the user,
wherein at least one of the plurality of cushions are specific cushions each being the cushion according to claim 1.

3. The mattress according to claim 2,

wherein the plurality of cushions include: as the specific cushions, a shoulder cushion for supporting a shoulder portion, a lumbar cushion for supporting a lumbar portion and a leg cushion for supporting a leg portion, and
all the upper cushions and the lower cushions of the shoulder cushion, the lumbar cushion and the leg cushion are identical in outer shape.

4. A cushion, comprising:

a predetermined number of constituent cushions, the predetermined number being three or more,
wherein each of the predetermined number of constituent cushions is formed with a filament three-dimensional bonded member such that resilient characteristics of an upper surface and a lower surface of each of the predetermined number of constituent cushions are equivalent,
the predetermined number of constituent cushions are arranged to overlap each other in an up/down direction,
resilient characteristics of the predetermined number of constituent cushions are different from each other, and
all the predetermined number of constituent cushions are identical in outer shape.

5. A mattress that supports a user in an upper sleeping posture, the mattress comprising:

a plurality of cushions that are aligned in a height direction of the user,
wherein at least one of the plurality of cushions is the cushion according to claim 4.

6. A mattress that supports a user in an upper sleeping posture, the mattress comprising:

a plurality of cushions that are aligned in a height direction of the user,
wherein the plurality of cushions include: a shoulder cushion for supporting a shoulder portion, a lumbar cushion for supporting a lumbar portion and a leg cushion for supporting a leg portion,
the shoulder cushion includes: a predetermined number of shoulder constituent cushions, the predetermined number being three or more,
each of the predetermined number of shoulder constituent cushions is formed with a filament three-dimensional bonded member such that resilient characteristics of an upper surface and a lower surface of each of the predetermined number of shoulder constituent cushions are equivalent,
the predetermined number of shoulder constituent cushions are arranged to overlap each other in an up/down direction,
the lumbar cushion includes: the predetermined number of lumbar constituent cushions,
each of the predetermined number of lumbar constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics of an upper surface and a lower surface of each of the predetermined number of lumbar constituent cushions are equivalent,
the predetermined number of lumbar constituent cushions are arranged to overlap each other in the up/down direction,
the leg cushion includes: the predetermined number of leg constituent cushions,
each of the predetermined number of leg constituent cushions is formed with the filament three-dimensional bonded member such that resilient characteristics of an upper surface and a lower surface of each of the predetermined number of leg constituent cushions are equivalent,
the predetermined number of leg constituent cushions are arranged to overlap each other in the up/down direction,
resilient characteristics of the predetermined number of shoulder constituent cushions are different from each other, and all the predetermined number of shoulder constituent cushions are identical in outer shape,
resilient characteristics of the predetermined number of lumbar constituent cushions are different from each other, and all the predetermined number of lumbar constituent cushions are identical in outer shape, and
resilient characteristics of the predetermined number of leg constituent cushions are different from each other, and all the predetermined number of leg constituent cushions are identical in outer shape.
Patent History
Publication number: 20260215593
Type: Application
Filed: Dec 6, 2023
Publication Date: Jul 30, 2026
Applicant: airweave inc. (Aichi)
Inventor: Motokuni TAKAOKA (Aichi)
Application Number: 19/144,503
Classifications
International Classification: A47C 27/12 (20060101); A47C 27/00 (20060101);