MATTRESS AND MATTRESS COVER

A cushion member includes: a mattress core member that is a three-dimensional bonded member formed with molten thermoplastic resin filaments, and is entirely formed in the shape of a flat plate; and an inner cover that accommodates the mattress core member. An exposure region is formed in the inner cover. The exposure region is a cutout that exposes an upper surface, a lower surface and side surfaces of one corner of the mattress core member, and is in a right-angled triangular shape in plain view. A mattress cover includes: an upper surface cover portion that covers an upper part of the mattress cushion; and a side surface cover portion that covers and elastically tightens side surfaces of the mattress cushion in a peripheral direction, and opens the exposure region of the inner cover such that the mattress core member is visually recognizable.

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Description
TECHNICAL FIELD

The present invention relates to a mattress which is formed with a cushion member and to a mattress cover.

In the present specification, terms such as an “up/down direction”, “upper” and “lower” which indicate directions are used to indicate directions in a posture in a state of use where a mattress is installed on a horizontal bed or the like, and such expressions are not intended to limit the configuration of the mattress.

BACKGROUND ART

In a typical conventional technique (Patent Document 1), a mattress cushion which can be divided into a plurality of cushion members in a longitudinal direction (that is, the height direction of a user) and in which the cushion members are arranged side by side is accommodated in a mattress cover. The mattress cover includes an upper surface side cover and a bottom surface side cover which can be connected and separated by a fastener that serves as a stretch prevention member for preventing the mattress cover from stretching in the longitudinal direction. The user is capable of lying on the upper surface side cover. The bottom surface side cover is formed in the shape of a cylinder having a bottom into which the mattress cushion can be fitted. The entire mattress core member which is a filament three-dimensional bonded member is accommodated in an inner cover, and thus the cushion members are formed.

RELATED ART DOCUMENT Patent Document

Patent Document 1: International Publication No. WO2018/150815

In the conventional technique described above, the entire mattress core member is accommodated in the inner cover, and thus the cushion members are formed, and the mattress cushion formed with the cushion members is fitted into the bottom surface side cover in the shape of a cylinder having a bottom and is covered by the upper surface side cover. Hence, the mattress core member of the cushion members cannot be visually recognized from outside, and furthermore, the mattress core member cannot be checked by touching it. Therefore, the configuration and the characteristic of the mattress core member such as hardness cannot be found, and the distribution of the hardness or the like in a thickness direction and a longitudinal direction cannot be found. Consequently, the user cannot select the cushion members, the mattress cushion and the mattress, and it is impossible to realize a mattress which achieves sleeping comfort suitable for the user.

Disclosure of the Invention

An object of the present invention is to provide a mattress in which a mattress core member can be visually recognized from outside, the characteristic of the mattress core member can easily be found and thus sleeping comfort suitable for a user is achieved.

In the conventional technique described above, the entire mattress cushion is accommodated in the mattress cover which can be opened and closed by the fastener. Hence, a large amount of labor is required for an operation of accommodating the mattress cushion in the mattress cover or removing the mattress cushion therefrom. Therefore, for example, the time and effort required for individual cleaning of the mattress cover and the mattress cushion is especially burdensome for people in the home.

In the conventional technique described above, the bottom surface side cover which can be connected to and separated from the upper surface side cover is in the shape of a cylinder having a bottom into which the mattress cushion can be fitted. Hence, when the thickness of the mattress cushion is larger than the height of the accommodation space of the bottom surface side cover, the mattress cushion cannot be accommodated whereas when the thickness is smaller than the height, a space is generated between the lower surface of the upper surface side cover and the upper surface of the mattress cushion, and thus the mattress cover collapses and deforms when the mattress is used, with the result that poor sleeping comfort and a poor aesthetic appearance are provided.

Another object of the present invention is to provide a mattress cover 10 in which a mattress cushion can be accommodated by an easy operation, from which the mattress cushion can be removed by an easy operation and which can be applied to mattress cushions having different thicknesses.

According to the present invention, a mattress 1 includes: a mattress cushion 20; and a mattress cover 10 which accommodates the mattress cushion 20 and on which a user is capable of lying, (a) the mattress cushion 20 is formed with a cushion member or a plurality of cushion members 21 to 23 each of which is the cushion member and which are arranged side by side, the cushion member 21 to 23 includes: a mattress core member 41 that includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and is entirely formed in the shape of a flat plate; and an inner cover 31 that accommodates the mattress core member 41, in the inner cover 31, an exposure region 37 is formed that exposes parts of an upper surface and a lower surface of the mattress core member 41, (b) the mattress cover 10 includes: an upper surface cover portion 11 that covers an upper part of the mattress cushion 20; and a side surface cover portion 12 that is connected to the upper surface cover portion 11, and covers and tightens side surfaces of the mattress cushion 20 and the mattress cover 10 opens the exposure region 37 of the inner cover 31 such that the mattress core member 41 is visually recognizable.

Advantages of the Invention

According to the present invention, the mattress cushion 20 is accommodated in the mattress cover 10, and thus the mattress is formed. Although the mattress cushion 20 may be formed by arranging a plurality of cushion members 21 to 23 side by side in the longitudinal direction, that is, in the height direction of the user, the mattress cushion 20 may be a cushion member which extends in the height direction.

The mattress core member 41 which is entirely formed in the shape of a flat plate is accommodated in the inner cover 31, and thus the cushion members 21 to 23 are formed. The mattress core member 41 includes the filament three-dimensional bonded member obtained by bonding the molten thermoplastic resin filaments in a three-dimensional net shape, and furthermore, for example, a soft urethane foam layer, nonwoven fabric and the like may be stacked.

The filament three-dimensional bonded member is suitable for a high resilient mattress, allows the user to turn over easily and has excellent breathability and body pressure dispersion, with the result that sleeping comfort is obtained with steam resistance and soft feeling. Since the filament three-dimensional bonded member has a high porosity, it can be washed with water, and drained and dried quickly, and thus it is easy to perform cleaning.

The inner cover 31 may be in a mesh form, and the material thereof is preferably a mesh fabric which is woven from polyester fibers having low water absorbency (high water repellency). In the inner cover 31, the exposure region 37 is formed which exposes parts of the upper surface and the lower surface of the mattress core member 41. The inner cover 31 serves to protect the mattress core member 41 accommodated therein from breaking or snapping filament pieces during handling or use, and to facilitate operations such as transportation.

In the mattress cover 10 which accommodates the mattress cushion 20, the side surface cover portion 12 is connected to the upper surface cover portion 11 which covers an upper part of the mattress cushion 20. The side surface cover portion 12 covers and tightens the side surfaces of the mattress cushion 20, and thus the mattress cushion 20 is unlikely to be separated from the mattress cover 10, and in the configuration in which the mattress cushion 20 includes a plurality of cushion members 21 to 23 arranged side by side, a state where the cushion members 21 to 23 are not separated in the longitudinal direction but are adjacent to each other is kept. As described above, the side surface cover portion 12 covers and tightens the side surfaces of the mattress cushion 20, and the mattress cover 10 accommodates the mattress cushion 20 by covering the mattress cushion 20 from above, with the result that the mattress cover 10 can be applied to mattress cushions having different thicknesses.

The mattress cover 10 opens the exposure region of the inner cover 31 such that the mattress core member 41 is visually recognizable. Hence, it is possible to visually check the mattress core member 41 exposed from the exposure region 37 of the mattress 1, and it is possible to check the mattress core member 41 such as by touching it, with the result that it is possible to easily find the configuration of the mattress core member 41 and furthermore physical properties such as hardness and the like. In this way, it is possible to select and realize the mattress cushion 20 which achieves sleeping comfort suitable for the user, for example, it is possible to reverse the cushion members 21 to 23 of the mattress cushion 20 in an up/down direction and it is possible to change and replace the cushion members 21 to 23 arranged side by side to change the combination thereof, with the result that it is possible to provide a mattress capable of realizing sleeping comfort suitable for the user.

According to the present invention, the side surface cover portion 12 includes: a side surface cover sheet 13 that is connected to the upper surface cover portion 11; and a tightening member 14 that is provided on the side surface cover sheet 13 and tightens the side surfaces of the mattress cushion 20 in a peripheral direction.

In the present invention, for example, typically, a lower part of the side surface cover sheet 13 is tightened by the tightening member 14 to the mattress cushion 20 and hence the side surfaces of the cushion members 21 to 23, and thus the mattress cover 10 is prevented from being separated from the mattress cushion 20 during the use of the mattress 1. When the mattress cushion 20 is formed with the cushion members 21 to 23 arranged side by side, a state where the adjacent cushion members 21 to 23 abut against each other is kept, the cushion members 21 to 23 are not separated and thus no gap is generated therebetween, with the result that the mattress cushion 20 can be comfortably used.

The tightening member 14 may be formed with, for example, a band-shaped elastic member extending in the longitudinal direction such as a rubber cord which has a contracting force in the peripheral direction along the side surfaces of the mattress cushion 20. The tightening member 14 may be a non-stretchable band-shaped member or the like, and may elastically tighten the side surface cover sheet 13 an example of which is lower parts to the side surfaces of the mattress core member 41 in the peripheral direction, for example, by utilizing elasticity of the mattress core member 41 itself. Examples of a material which can be used as the non-stretchable band-shaped member include a woven tape formed of synthetic fibers and the like.

According to the present invention, a display portion 44, 45 that displays the characteristic of the mattress core member 41 exposed from the exposure region 37 is formed near the exposure region 37 on the outer surface of the inner cover 31.

In the present invention, the display portion 44, 45 which displays the characteristic of the mattress core member 41 is provided near the exposure region 37 on the outer surface of the inner cover 31, and thus the surface of the mattress core member 41 can be visually recognized from the exposure region 37, and simultaneously, the characteristic of the mattress core member 41 and hence the cushion members 21 to 23 can easily be found. Examples of the characteristic of the mattress core member 41 may include physical properties such as the hardness, including the softness, and the resilience of the mattress core member 41, a fit which may be expressed as light, moist or the like, a quality, sleeping comfort which indicates the evaluation of the mattress core member 41 obtained when the user lies on the mattress core member 41 to sleep and the like. The display portion 44, 45 may be expressed, for example, by colors, characters, symbols, figures and the like corresponding to hardness. For example, the colors may be set as white, light gray, gray and dark gray in the order of soft characteristics to hard characteristics, and the characters may be set as, for example, “1 SOFT”, “2 MODERATE”, “3 FIRM” and “4 EXTRA FIRM” as described later. When the mattress core member 41 is formed with a plurality of layers having different harnesses in the thickness direction, the characteristic expressed by the display portion 44, 45 may indicate the hardness of a layer near the surface of the mattress core member 41 exposed from the exposure region 37, may indicate the characteristic of the layers of the mattress core member 41 in the thickness direction, may indicate sleeping comfort which indicates the evaluation of the mattress core member 41 obtained when the mattress core member 41 is used or may indicate another characteristic or the like.

According to the present invention, the mattress core member 41 of the cushion member 21 to 23 is a rectangular, and the exposure region 37 of the inner cover 31 is formed with a cutout that exposes an upper surface, a lower surface and side surfaces of at least one corner 37 of the mattress core member 41, and is in a right-angled triangular shape in plan view.

In the present invention, the mattress core member 41 is rectangular, that is, is rectangular or square right-angled quadrilateral in plan view, and in the inner cover 31 in which the mattress core member 41 is accommodated, the exposure region 37 is formed in at least one of four corners by the cutout in a right-angled triangular shape in plan view. The exposure region 37 in the corner exposes the upper surface, the lower surface and the side surfaces of the mattress core member 41.

Since the mattress cover 10 opens the exposure region 37 of the inner cover 31 such that the mattress core member 41 is visually recognizable, the exposure region 37 can be visually recognized in a state where the mattress cushion 20 is covered with the mattress cover 10, that is, without the mattress cover 10 being removed. Hence, it is possible to easily find sleeping comfort caused by the mattress core member 41 exposed from the exposure region 37 and the like.

Since the mattress core member 41 is exposed to the cutout in a right-angled triangular shape in plan view, for example, the user can pinch and press both the upper and lower surfaces of the mattress core member 41 between the thumb and the index finger to make contact therewith. In this way, the user can find the characteristic of the harness or the like of the mattress core member 41, and thus it is possible to select and obtain suitable sleeping comfort.

According to the present invention, a display portion 44, 45 is formed along the hypotenuse of the right-angled triangular exposure region 37, and the display portion 44, 45 displays the characteristic of the mattress core member 41 exposed from the exposure region 37.

In the present invention, the display portion 44, 45 which displays the characteristic of the mattress core member 41 is formed along the hypotenuse of the right-angled triangular exposure region 37, and thus the user can grasp the details of the display of the display portion 44, 45 simultaneously when the user visually recognizes the exposure region 37. Hence, it is possible to easily find sleeping comfort caused by the characteristic of the cushion members 21 to 23 and the like. Since the hypotenuse of a right-angled triangle is longer than the other two sides which enclose the right angle, the area of the display portion 44, 45 formed near the exposure region 37 is increased, and thus the display portion 44, 45 can easily be seen.

According to the present invention, a mattress 1 includes: a mattress cushion 20; and a mattress cover 10 which accommodates the mattress cushion 20 and on which a user is capable of lying, (a) the mattress cushion 20 is formed with a cushion member or a plurality of cushion members 21 to 23 each of which is the cushion member and which are arranged side by side, the cushion member 21 to 23 includes: a mattress core member 41 that includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and is entirely formed in the shape of a flat plate; and an inner cover 31 that accommodates the mattress core member 41, in the inner cover 31, an exposure region 37 is formed that exposes parts of an upper surface and a lower surface of the mattress core member 41, (b) the mattress cover 10 includes: an upper surface cover portion 11 that covers an upper part of the mattress cushion 20; and a side surface cover portion 12 that is connected to the upper surface cover portion 11, and covers and tightens an area extending from side surfaces of the mattress cushion 20 to a peripheral edge portion of a lower surface of the mattress cushion 20 and the mattress cover 10 opens the exposure region 37 of the inner cover 31 such that the mattress core member 41 is visually recognizable.

In the present invention, the side surface cover portion 12 connected to the upper surface cover portion 11 of the mattress cover 10 covers and tightens the area extending from the side surfaces of the mattress cushion 20 to the peripheral edge portion of the lower surface, and thus the mattress cover 10 is more reliably prevented from being separated from the mattress cushion 20 during the use of the mattress 1. When the mattress cushion 20 is formed with the cushion members 21 to 23 arranged side by side, the state where the adjacent cushion members 21 to 23 abut against each other is more reliably kept, the cushion members 21 to 23 are not separated and thus a gap is more reliably prevented from being generated therebetween.

According to the present invention, a cushion sheet 52 is stacked between the mattress cushion 20 and the upper surface cover portion 11 of the mattress cover 10.

In the present invention, the cushion sheet 52 which is an elastic sheet member is stacked on the mattress cushion 20, and thus it is possible to obtain more comfortable sleeping comfort corresponding to the request of the user.

According to the present invention, a cushion member or a plurality of cushion members 21 to 23 each of which is the cushion member and which are arranged side by side, form a mattress cushion 20 accommodated in a mattress cover 10 on which a user is capable of lying, the cushion member 21 to 23 includes: a mattress core member 41 that includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and is entirely formed in the shape of a flat plate; and an inner cover 31 that accommodates the mattress core member 41 and in the inner cover 31, an exposure region 37 is formed that exposes parts of an upper surface and a lower surface of the mattress core member 41.

In the cushion members 21 to 23 of the present invention, in the inner cover 31 which accommodates the mattress core member 41, the exposure region 37 is formed which exposes parts of the upper surface and the lower surface of the mattress core member 41. Hence, as described previously, it is possible to visually check the mattress core member 41 exposed from the exposure region 37, and it is possible to check the mattress core member 41 such as by touching it, with the result that it is possible to easily find the characteristic, the physical properties such as hardness, the configuration and the like of the mattress core member 41. In this way, it is possible to select and realize the mattress cushion 20 which achieves sleeping comfort suitable for the user, for example, it is possible to reverse the cushion members 21 to 23 of the mattress cushion 20 in the up/down direction and it is possible to change and replace the cushion members 21 to 23 arranged side by side to change the combination thereof, with the result that it is possible to provide a mattress capable of realizing sleeping comfort suitable for the user.

According to the present invention, a mattress cover 10 accommodates a mattress cushion 20 formed with a cushion member or a plurality of cushion members 21 to 23 each of which is the cushion member and which are arranged side by side, a user is capable of lying on the mattress cover 10 and the mattress cover 10 includes: an upper surface cover portion 11 that covers an upper part of the mattress cushion 20; and a side surface cover portion 12 that is connected to the upper surface cover portion 11, and covers and tightens side surfaces of the mattress cushion 20.

In the present invention, the mattress cushion 20 is accommodated in the mattress cover 10, and thus the mattress is formed. Although in the mattress cushion 20, a plurality of cushion members 21 to 23 may be arranged side by side in the longitudinal direction, that is, in the height direction of the user, a cushion member which extends in the longitudinal direction may be provided.

In the mattress cover 10 which accommodated the mattress cushion 20, the side surface cover portion 12 is connected to the upper surface cover portion 11 which covers an upper part of the mattress cushion 20. The side surface cover portion 12 covers and tightens the side surfaces of the mattress cushion 20, and thus the mattress cushion 20 is unlikely to be separated from the mattress cover 10, and in the configuration in which the mattress cushion 20 includes a plurality of cushion members 21 to 23 arranged side by side, a state where the cushion members 21 to 23 are not separated in the longitudinal direction but are adjacent to each other is kept. The side surface cover portion 12 covers and tightens the side surfaces of the mattress cushion 20, and the mattress cover 10 accommodates the mattress cushion 20 by covering the mattress cushion 20 from above, with the result that the mattress cover 10 can be applied to mattress cushions having different thicknesses.

Since the mattress cover 10 opens a lower part, the mattress cover 10 covers the entire mattress cushion 20 to be able to easily accommodate the mattress cushion 20, and it is also possible to easily remove and separate the mattress cushion 20 accommodated. Hence, labor for an operation of accommodating the mattress cushion 20 in the mattress cover 10 or removing and separating the mattress cushion 20 is reduced.

According to the present invention, the side surface cover portion 12 includes: a side surface cover sheet 13 that is connected to the upper surface cover portion 11; and a tightening member 14 that is provided on the side surface cover sheet 13 and tightens the side surfaces of the mattress cushion 20 in a peripheral direction.

In the present invention, on the side surface cover sheet 13 in the side surface cover portion 12 of the mattress cover 10, for example, typically, the tightening member 14 which tightens the side surfaces of the mattress cushion 20 in the peripheral direction is provided at a lower part thereof, and thus it is easy to cover the mattress cushion 20 with the mattress cover 10 and accommodate the mattress cushion 20 in the mattress cover 10 or to remove the mattress cushion 20.

According to the present invention, the side surface cover portion 12 includes: a side surface cover sheet 13 that is connected to the upper surface cover portion 11, and covers an area extending from the side surfaces of the mattress cushion 20 to a peripheral edge portion of a lower surface of the mattress cushion 20; and a tightening member 14 that is provided on a part of the side surface cover sheet 13 which covers the peripheral edge portion of the lower surface of the mattress cushion 20, and tightens the side surfaces of the mattress cushion 20 in a peripheral direction.

In the present invention, the side surface cover sheet 13 in the side surface cover portion 12 of the mattress cover 10 covers the area extending from the side surfaces of the mattress cushion 20 to the peripheral edge portion of the lower surface of the mattress cushion 20, and the tightening member is provided on the part of the side surface cover sheet which covers the peripheral edge portion of the lower surface of the mattress cushion 20. Hence, it is easy to cover the mattress cushion 20 with the mattress cover 10 and accommodate the mattress cushion 20 in the mattress cover 10, the mattress cushion 20 accommodated can be prevented from being undesirably separated and no problem occurs in the peripheral edge portion of the lower surface of the mattress cushion 20 in the side surface cover sheet when the mattress cushion 20 is removed from the mattress cover 10.

According to the present invention, the tightening member 14 is formed with a band-shaped elastic member that exerts a contracting force in a longitudinal direction.

According to the present invention, the tightening member 14 is formed with a non-stretchable band-shaped member, and tightens the side surfaces by utilizing elasticity of the mattress cushion 20.

In the present invention, the tightening member 14 may be band-shaped and elongated and may be formed with an elastic member, or may be formed of a non-stretchable material. In the configuration in which the tightening member 14 is not stretchable, the elasticity of the mattress cushion 20 may be utilized to elastically tighten the side surface cover sheet 13 an example of which is lower parts to the side surfaces of the mattress cushion 20 in the peripheral direction. Instead of the embodiment in which the non-stretchable band-shaped member is adopted as the tightening member 14, the side surface cover sheet 13 may be designed to function as a non-stretchable tightening member by using a canvas fabric or the like. In order to enhance breathability, it is desirable to provide a plurality of air vents or a mesh fabric having excellent breathability in the side surface cover sheet 13.

BRIEF DESCRIPTION OF DRAWINGS

The objects, the features and the effects of the present invention will be clearer from the following description given with reference to drawings.

FIG. 1 a perspective view showing a mattress 1 according to an embodiment of the present invention with a part of a mattress cover 10 peeled off;

FIG. 2 a perspective view showing the overall shape of the mattress 1;

FIG. 3 a bottom view showing the mattress cover 10 in its unfolded natural state with the cushion members 21 to 23 removed and no external force acting thereon;

FIG. 4 a perspective view of a mattress cushion 20 formed with three cushion members 21 to 23 arranged side by side;

FIG. 5 a perspective view showing mattress core members 41 to 43 which respectively form the cushion members 21 to 23 and inner covers 31 to 33 which accommodate the mattress core members 41 to 43;

FIG. 6 a perspective view when the mattress cushion 20 shown in FIG. 4 is viewed from below FIG. 4;

FIG. 7 a diagram showing the outer shape of the inner cover 31, FIG. 7(1) is a plan view of the inner cover 31, FIG. 7(2) is a right side view of the inner cover 31 and FIG. 7(3) is a bottom view of the inner cover 31;

FIG. 8 a plan view showing a state where a display portion 44 shows the characteristic of the mattress core member 41;

FIG. 9 a cross-sectional view taken along line IX-IX in FIG. 1 in a state where as shown in FIG. 2, the mattress cushion 20 is accommodated in the mattress cover 10 shown in FIG. 1;

FIG. 10 a cross-sectional view taken along line X-X in FIG. 1 in the state where as shown in FIG. 2, the mattress cushion 20 is accommodated in the mattress cover 10;

FIG. 11 a cross-sectional view showing a part in another embodiment of the present invention;

FIG. 12 a cross-sectional view showing a part in yet another embodiment of the present invention; and

FIG. 13 a perspective view showing a cushion member 21 in another embodiment of the present invention.

 DESCRIPTION OF EMBODIMENTS

FIG. 1 is a perspective view showing a mattress 1 according to an embodiment of the present invention with a part of a mattress cover 10 peeled off, and FIG. 2 is a perspective view showing the overall shape of the mattress 1. A forward/backward direction X (a longitudinal direction, a height direction), a left/right direction Y and an up/down direction Z (thickness direction) relative to the mattress 1 are as shown in FIG. 1. In FIG. 1, for ease of understanding of the internal configuration of the mattress 1, the approximate positions of the boundaries of a plurality of (for example, three) cushion members 21 to 23 arranged side by side adjacent to each other are shown by imaginary lines.

The mattress 1 includes the mattress cover 10 which covers the entire outer surface thereof and on which a user is capable of lying and a mattress cushion 20 which is accommodated therein. The mattress 1 is formed in the shape of a rectangular parallelepiped having sides in the forward/backward direction X, the left/right direction Y and the up/down direction Z when viewed overall, a dimension in the left/right direction Y is slightly smaller than a dimension in the forward/backward direction X and a dimension in the up/down direction Z is sufficiently smaller than the dimension in the left/right direction Y. In an example, the dimension of the mattress 1 in the forward/backward direction X may be 195 to 200 cm, the dimension in the left/right direction Y may be 90 to 140 cm and the dimension in the up/down direction Z may be 11.5 cm.

The mattress cushion 20 is formed to be dividable into the cushion members 21 to 23. The mattress 1 is generally placed on a horizontal floor, a bed or the like, and is used in a form in which the user lies on the mattress 1. When the mattress 1 is used as described above, the up/down direction Z of the mattress 1 coincides with a vertical direction. As described above, the mattress 1 is set such that the size in the forward/backward direction X is longer, and can be suitably used in a form in which the forward/backward direction X substantially coincides with the height direction of the user.

FIG. 3 is a bottom view showing the mattress cover 10 in its unfolded natural state with the cushion members 21 to 23 removed and no external force acting thereon. The mattress cover 10 includes: an upper surface cover portion 11 which covers an upper part of the mattress cushion 20; a side surface cover portion 12 which is connected to the upper surface cover portion 11 and covers and tightens the side surfaces of the mattress cushion 20. The side surface cover portion 12 includes: a side surface cover sheet 13 (individually indicated by 13a to 13d) which is connected to the upper surface cover portion 11; and a tightening member 14 which is provided on a lower part of the side surface cover sheet 13 and tightens the side surfaces of the mattress cushion 20 in a peripheral direction. The side surface cover sheets 13a to 13d adjacent in the peripheral direction are sewn together as indicated by dashed lines in FIG. 3.

The mattress cover 10 is open downward (front side of FIG. 3). Hence, the lower surface of the mattress cushion 20 and hence the lower surfaces of the cushion members 21 to 23 of the mattress cushion 20 can be seen without the mattress cover 10 being peeled off.

FIG. 4 is a perspective view of the mattress cushion 20 formed with the three cushion members 21 to 23 arranged side by side, FIG. 5 is a perspective view showing mattress core members 41 to 43 which respectively form the cushion members 21 to 23 and inner covers 31 to 33 which respectively accommodate the mattress core members 41 to 43 and FIG. 6 is a perspective view when the mattress cushion 20 shown in FIG. 4 is viewed from below FIG. 4. In the following description, in order to avoid redundancy, the cushion member 21 will be mainly described, and the same description of the remaining cushion members 22 and 23 may be omitted. The mattress core member 41 of the cushion member 21 is rectangular and is entirely formed in the shape of a flat plate, and is rectangular or square right-angled quadrilateral in plan view. The mattress core member 41 includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and furthermore, a soft urethane foam layer, nonwoven fabric and the like may be stacked.

The filament three-dimensional bonded member may have, for example, a thickness of 10 to 25 cm, a filament diameter of 0.5 to 2 mm and a bulk density of 30 to 150kg/m3, and may have, at both end portions in the thickness direction, a smooth surface layer in which the density of filaments is higher than that in a center portion in the thickness direction.

When the thickness of the filament three-dimensional bonded member is less than 10 cm, the filament three-dimensional bonded member itself easily twists and overlaps vertically in the up/down direction, and thus it is difficult to transmit a crimping force in the longitudinal direction. By contrast, when the thickness exceeds 25 cm, the filament three-dimensional bonded member becomes heavy and difficult to convey.

When the filament diameter in the filament three-dimensional bonded member is less than 0.5 mm, in the surface of the filaments, a water drainage time and a drying time after washing are longer. By contrast, when the filament diameter exceeds 2 mm, the soft feel of the filament three-dimensional bonded member is easily lost.

The bulk density of the filament three-dimensional bonded member can be measured, for example, by a measurement method using a measurement sample in the shape of a rectangular parallelepiped. In the measurement method, the mass W (kg) of the measurement sample and the sizes (m) of the measurement sample in the directions (the longitudinal direction, the lateral direction and the height direction) thereof are first measured. The sizes (m) of the measurement sample in the directions (the longitudinal direction, the lateral direction and the height direction) thereof are multiplied, and thus the volume V (m3) of the measurement sample is calculated. Then, the bulk density (kg/m3) is calculated by dividing the mass W (kg) of the measurement sample by the volume V (m3) of the measurement sample. When the bulk density of the filament three-dimensional bonded member is less than 30 kg/m3, the filament three-dimensional 41 bonded member itself is easily deformed in the longitudinal direction, and thus in the surface of the mattress, oval grooves and recesses are easily generated. By contrast, when the bulk density exceeds 150 kg/m3, the filament three-dimensional bonded member becomes heavy and difficult to convey.

In the manufacturing process of the filament three-dimensional bonded member of the mattress core member 41, a thermoplastic resin in a molten state is extruded downward in the vertical direction from a plurality of nozzles arranged horizontally. In this way, a molten filament having a cross-sectional diameter of about 1 mm is dropped into cooling water, a loop is formed by the buoyancy of the water and simultaneously, a plurality of molten filaments where the loop is formed are three-dimensionally fused, with the result that a resilient filament three-dimensional bonded member is obtained. Here, the width of the molten filament group is restricted by a chute, a drawing machine and the like, and thus the smooth surface layer in which the density of the filaments is higher than that in the center portion in the thickness direction can be formed at both end portions in the thickness direction.

In the mattress core member 41, the smooth surface layer in which the density of the filaments is higher than that in the center portion in the thickness direction is formed at both end portions in the thickness direction, and the thickness, the filament diameter and the bulk density are caused to fall within the ranges described above, with the result that it is possible to prevent, as much as possible, the occurrence of an event in which the cushion members 21 to 23 are deformed in the longitudinal direction to form oval grooves in the surface of the mattress 1 without the drainage property and the drying property of the filament three-dimensional bonded member 41 being impaired.

Each of the cushion members 21 to 23 may be formed with a filament three-dimensional bonded member which is made of resin and includes the smooth surface layer (in which the density of the filaments is higher than that in the center portion in the thickness direction) at both end portions in the thickness direction. Each of the cushion members 21 to 23 has a structure in which three thin sheets of filament three-dimensional bonded member in the shape of a rectangular parallelepiped (referred to as a lower layer, a middle layer and an upper layer for convenience) are stacked upward from below. Each of the cushion members 21 to 23 may be formed by bonding separately formed layers with an adhesive.

In the inner covers 31 to 33, exposure regions 37 to 39 which expose parts of the upper surfaces and the lower surfaces of the mattress core members 41 to 43 are respectively formed.

FIG. 7 is a diagram showing the outer shape of the inner cover 31. In FIG. 7, FIG. 7 (1) is a plan view of the inner cover 31, FIG. 7(2) is a right side view of the inner cover 31 and FIG. 7(3) is a bottom view of the inner cover 31. The inner cover 31 includes an upper surface inner sheet 34, a lower surface inner sheet 35 and a side surface inner sheet 36. The exposure region 37 of the inner cover 31 exposes an upper surface, a lower surface and side surfaces of one corner among the four corners of the mattress core member 41. The exposure region 37 is formed in at least one of the four corners with a cutout in a right-angled triangular shape in plan view. In the inner cover 31, the exposure region 37 is formed in at least one of the four corners with the cutout in a right-angled triangular shape in plan view. The exposure region 37 in the corner exposes the upper surface, the lower surface and the side surfaces of the mattress core member 41.

The side surfaces indicated by reference signs 21a to 21d are connected counterclockwise in FIG. 7(1) from the exposure region 37 in the peripheral direction, and thus the inner cover 31 is formed in the shape of a pentagon in plan view. In order to be able to accommodate the mattress core member 41 in the inner cover 31 and to remove the mattress core member 41 from the inner cover 31, in the upper surface inner sheet 34 and the side surface inner sheet 36, a fastener 51 which uses a woven tape extending in a range represented by a large number of protrusions is provided from a substantially central position of the side surface 21b in the up/down direction in FIG. 7(1) through the side surface 21c to a substantially central position of the side surface 21c in the up/down direction in FIG. 7(1) such that the fastener 51 can be opened and closed.

As is clear from FIGS. 1 and 3 described above, the mattress cover 10 opens the exposure region 37 of the inner cover 31 such that the mattress core member 41 is visually recognizable. Hence, in a state where the mattress cover 10 covers the mattress cushion 20, the exposure region 37 of the inner cover 31 can be visually recognized without the mattress cover 10 being removed, and the user can touch the mattress core member 41 exposed from the exposure region 37. Therefore, it is possible to easily find the characteristic of the mattress core member 41 exposed from the exposure region 37 such as the hardness described above.

In the upper surface inner sheet 34 and the lower surface inner sheet 35 of the inner cover 31, display portions 44 and 45 are respectively formed along the hypotenuses of the right-angled triangular exposure region 37. The display portions 44 and 45 display the characteristics of the mattress core member 41 exposed from the exposure region 37. Along the hypotenuses of exposure regions 38 and 39 of inner covers 32 and 33, display portions 46, 47, 48 and 49 are formed in the same manner.

FIG. 8 is a plan view showing a state where the display portion 44 displays the characteristic of the mattress core member 41. In the display portion 44, as examples, “1 SOFT”, “2 MODERATE”, “3 FIRM” and “4 EXTRA FIRM” obtained by combining numbers and English letters are displayed as shown in FIG. 8(1) to 8(4). The numbers and the English letters indicate the characteristics of the mattress core member 41.

The display portions 44 to 49 which display the characteristics of the mattress core members 41 are formed along the hypotenuses of the right-angled triangular exposure regions 37 to 39, and thus the user can grasp the details of the display of the display portions 44 to 49 simultaneously when the user visually recognizes the exposure regions 37 to 39. Hence, it is possible to easily find sleeping comfort caused by the characteristics of the cushion members 21 to 23 and the like. Since the hypotenuse of a right-angled triangle is longer than the other two sides which enclose the right angle, the area of the display portion formed near the exposure region is increased, and thus the display portion can easily be seen. The remaining display portions 45 to 49 may be formed in the same manner.

FIG. 9 is a cross-sectional view taken along line IX-IX in FIG. 1 in a state where as shown in FIG. 2, the mattress cushion 20 is accommodated in the mattress cover 10 shown in FIG. 1. FIG. 10 is a cross-sectional view taken along line X-X in FIG. 1 in the state where as shown in FIG. 2, the mattress cushion 20 is accommodated in the mattress cover 10. The mattress cover 10 includes: the upper surface cover portion 11 which covers an upper part of the mattress cushion 20; and the side surface cover portion 12 which is connected to the upper surface cover portion 11 and covers and tightens the side surfaces of the mattress cushion 20. The mattress cover 10 opens the exposure region 37 of the inner cover 31 such that the mattress core member 41 is visually recognizable. The upper surface cover portion 11 is formed by quilting (stitching) an upper surface cover sheet 15, a lower surface cover sheet 16 and a cushion member 17 which is interposed therebetween and has elasticity in the thickness direction. The peripheral portion 24 of the upper surface cover sheet 15 and the lower surface cover sheet 16 in the upper surface cover portion 11 protrudes outward (rightward in FIGS. 9 and 10), and is sewn to a folded portion 25 protruding outward (rightward in FIGS. 9 and 10) of an upper part of the side surface cover sheet 13 of the side surface cover portion 12 using a hem tape 26, with the result that a sewn portion 27 is formed. A lower part 28 of the side surface cover sheet 13 of the side surface cover portion 12 includes an accommodation portion formed by folding a part of the side surface cover sheet 13 inward (leftward in FIGS. 9 and 10), and the tightening member 14 is accommodated in the accommodation portion. The tightening member 14 is a band-shaped elastic member such as a rubber cord which is formed in the shape of an endless ring around the entire periphery of the side surface cover portion 12, and elastically tightens the lower parts of the side surfaces of the mattress cushion 20 in the peripheral direction by the elastic contracting force thereof. As in the bottom view shown in FIG. 3 in a natural state of the mattress cover 10, the tightening member 14 is kept in a ring shape inward of the outer peripheral edge of the upper surface cover portion 11 by the elastic contracting force of the tightening member 14. The tightening members 14 may be spaced in the peripheral direction and attached to the lower part of the side surface cover sheet 13. As described above, the side surface cover portion 12 covers and tightens the side surfaces of the mattress cushion 20, and the mattress cover 10 covers the mattress cushion 20 from above and accommodates the mattress cushion 20, with the result that the mattress cover 10 can be applied to mattress cushions having different thicknesses. For example, when the thickness of the mattress cushion 20 is large, the tightening member 14 is located at middle parts of the side surfaces of the mattress cushion 20 or at parts close to the tops thereof whereas when the thickness of the mattress cushion 20 is small, as described above, the tightening member 14 is located at the lower parts or is located from the side surfaces of the mattress cushion 20 to the peripheral edge portion 57 of the lower surface thereof as shown in FIG. 12 to be described later.

FIG. 11 is a cross-sectional view showing a part in another embodiment of the present invention. FIG. 11 corresponds to the configuration shown in FIG. 9 in the embodiment described above. In this embodiment, a cushion sheet 52 is stacked between the mattress cushion 20 and the upper surface cover portion 11 of the mattress cover 10. Although in FIG. 11, the upper surface cover portion 11 is shown as a single upper surface cover sheet, the upper surface cover portion 11 may have the configuration shown in FIG. 9 or may be realized by another configuration. In the cushion sheet 52, a cushion member 55 which has elasticity in the thickness direction is interposed between upper and lower sheets 53. Although the cushion sheet 52 may be fixed to the lower surface of the upper surface cover portion 11, the cushion sheet 52 may be separated from the upper surface cover portion 11.

FIG. 12 is a cross-sectional view showing a part in yet another embodiment of the present invention. FIG. 11 corresponds to the configuration shown in FIG. 9 in the embodiment described above. Although this embodiment is similar to the embodiments described above, it is noteworthy that a lower part 29 of the side surface cover portion 12 covers an area extending from the side surfaces of the mattress cushion 20 to a peripheral edge portion 57 of the lower surface of the mattress cushion 20, the side surface cover sheet 13 of the side surface cover portion 12 includes an accommodation portion formed by folding a part of the side surface cover sheet 13 inward (upward in FIG. 12) near the peripheral edge portion 57 and the tightening member 14 is accommodated in the accommodation portion. The tightening member 14 elastically tightens the mattress cushion 20 from the side surfaces to the peripheral edge portion 57 of the lower surface.

FIG. 13 is a perspective view showing a cushion member 21 in another embodiment of the present invention. The configurations corresponding to those in the embodiments described above are identified with the same reference signs. An exposure region 37 from which a part of the mattress core member 41 is exposed may be formed in a position other than the corners described previously on the upper and lower surfaces of the inner cover 31 of the cushion member 21, for example, in a position close to the center. A display portion 44 is formed near the exposure region 37.

INDUSTRIAL APPLICABILITY

The present invention can be utilized for a mattress which is formed with a cushion member.

Although the embodiments of the present disclosure have been described in detail above, the present invention is not limited to the embodiments described above, and various changes, improvements and the like can be made without departing from the spirit of the present invention. It is needless to say that all or part of constituent elements of the embodiments described above can be combined as necessary to the extent that they do not contradict each other.

REFERENCE SIGNS LIST

    • 1 mattress
    • 10 mattress cover
    • 11 upper surface cover portion
    • 12 side surface cover portion
    • 13, 13a to 13d side surface cover sheet
    • 14 tightening member
    • 15 upper surface cover sheet
    • 16 lower surface cover sheet
    • 17 cushion member
    • 20 mattress cushion
    • 21 to 23 cushion member
    • 24 peripheral portion
    • 28 lower part
    • 31 to 33 inner cover
    • 34 upper surface inner sheet
    • 35 lower surface inner sheet
    • 36 side surface inner sheet
    • 37 to 39, 59 exposure region
    • 41 to 43 mattress core member
    • 44, 45, 46, 47, 48, 49 display portion
    • 51 fastener
    • 52 cushion sheet
    • 57 peripheral edge portion

Claims

1. 1. A mattress comprising:

a mattress cushion; and
a mattress cover which accommodates the mattress cushion and on which a user is capable of lying,
wherein (a) the mattress cushion is formed with a cushion member or a plurality of cushion members each of which is the cushion member and which are arranged side by side,
the cushion member includes: a mattress core member that includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and is entirely formed in a shape of a flat plate; and an inner cover that accommodates the mattress core member,
in the inner cover, an exposure region is formed that exposes parts of an upper surface and a lower surface of the mattress core member,
(b) the mattress cover includes: an upper surface cover portion that covers an upper part of the mattress cushion; and a side surface cover portion that is connected to the upper surface cover portion, and covers and tightens side surfaces of the mattress cushion and
the mattress cover opens the exposure region of the inner cover such that the mattress core member is visually recognizable.

2. The mattress according to claim 1,

wherein the side surface cover portion includes: a side surface cover sheet that is connected to the upper surface cover portion; and a tightening member that is provided on the side surface cover sheet and tightens the side surfaces of the mattress cushion in a peripheral direction.

3. The mattress according to claim 1,

wherein a display portion that displays a characteristic of the mattress core member exposed from the exposure region is formed near the exposure region on an outer surface of the inner cover.

4. The mattress according to claim 1,

wherein the mattress core member of the cushion member is a rectangular, and
the exposure region of the inner cover is formed with a cutout that exposes an upper surface, a lower surface and side surfaces of at least one corner of the mattress core member, and is in a right-angled triangular shape in plan view.

5. The mattress according to claim 4,

wherein a display portion is formed along a hypotenuse of the right-angled triangular exposure region, and
the display portion displays a characteristic of the mattress core member exposed from the exposure region.

6. A mattress comprising:

a mattress cushion; and
a mattress cover which accommodates the mattress cushion and on which a user is capable of lying,
wherein (a) the mattress cushion is formed with a cushion member or a plurality of cushion members each of which is the cushion member and which are arranged side by side,
the cushion member includes: a mattress core member that includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and is entirely formed in a shape of a flat plate; and an inner cover that accommodates the mattress core member,
in the inner cover, an exposure region is formed that exposes parts of an upper surface and a lower surface of the mattress core member,
(b) the mattress cover includes: an upper surface cover portion that covers an upper part of the mattress cushion; and a side surface cover portion that is connected to the upper surface cover portion, and covers and tightens an area extending from side surfaces of the mattress cushion to a peripheral edge portion of a lower surface of the mattress cushion and
the mattress cover opens the exposure region of the inner cover such that the mattress core member is visually recognizable.

7. The mattress according to claim 1,

wherein a cushion sheet is stacked between the mattress cushion and the upper surface cover portion of the mattress cover.

8. A cushion member or a plurality of cushion members each of which is the cushion member and which are arranged side by side,

wherein the cushion member or the plurality of cushion members form a mattress cushion accommodated in a mattress cover on which a user is capable of lying,
the cushion member includes: a mattress core member that includes a filament three-dimensional bonded member obtained by bonding molten thermoplastic resin filaments in a three-dimensional net shape, and is entirely formed in a shape of a flat plate; and an inner cover that accommodates the mattress core member and
in the inner cover, an exposure region is formed that exposes parts of an upper surface and a lower surface of the mattress core member.

9. A mattress cover that accommodates a mattress cushion formed with a cushion member or a plurality of cushion members each of which is the cushion member and which are arranged side by side, a user being capable of lying on the mattress cover, the mattress cover comprising:

an upper surface cover portion that covers an upper part of the mattress cushion; and
a side surface cover portion that is connected to the upper surface cover portion, and covers and tightens side surfaces of the mattress cushion.

10. The mattress cover according to claim 9,

wherein the side surface cover portion includes: a side surface cover sheet that is connected to the upper surface cover portion; and a tightening member that is provided on the side surface cover sheet and tightens the side surfaces of the mattress cushion in a peripheral direction.

11. The mattress cover according to claim 9,

wherein the side surface cover portion includes: a side surface cover sheet that is connected to the upper surface cover portion, and covers an area extending from the side surfaces of the mattress cushion to a peripheral edge portion of a lower surface of the mattress cushion; and a tightening member that is provided on a part of the side surface cover sheet which covers the peripheral edge portion of the lower surface of the mattress cushion, and tightens the side surfaces of the mattress cushion in a peripheral direction.

12. The mattress cover according to claim 10 or 11,

wherein the tightening member is formed with a band-shaped elastic member that exerts a contracting force in a longitudinal direction.

13. The mattress cover according to claim 10,

wherein the tightening member is formed with a non-stretchable band-shaped member, and tightens the side surfaces by utilizing elasticity of the mattress cushion.
Patent History
Publication number: 20260232117
Type: Application
Filed: Jan 24, 2024
Publication Date: Aug 13, 2026
Inventors: Kyohei SUEKI (Aichi), Sae INOUE (Aichi)
Application Number: 19/149,188
Classifications
International Classification: A47C 27/14 (20060101); A47C 31/10 (20060101);