U.S. patent application number 10/215740 was filed with the patent office on 2003-02-27 for cushion and mold for cushion.
Invention is credited to Kawamura, Shoji, Kubota, Hirotoshi, Sasaki, Masao, Takeda, Yukihiro, Tsuruhashi, Kenichi.
Application Number | 20030037377 10/215740 |
Document ID | / |
Family ID | 43333340 |
Filed Date | 2003-02-27 |
United States Patent
Application |
20030037377 |
Kind Code |
A1 |
Kawamura, Shoji ; et
al. |
February 27, 2003 |
Cushion and mold for cushion
Abstract
A bed cushion providing a soft feeling without bottomed feeling
and providing a cushionability even against a small load and a
durability, and a bed using the cushion; a forming die for cushion
capable of smoothly and neatly releasing a product by reducing a
sticky feeling and a blocking produced when releasing the cushion
formed by using elastomer; the cushion, comprising thin-walled
partition walls erected parallel with each other generally in a
lattice shape in plan view, whereby a soft contact feeling near a
water bed can be provided while preventing air blow noise from
being produced by a user.
Inventors: |
Kawamura, Shoji; (Ohme-shi,
JP) ; Takeda, Yukihiro; (Fujieda-shi, JP) ;
Tsuruhashi, Kenichi; (Yaizu-shi, JP) ; Kubota,
Hirotoshi; (Haibara-gun, JP) ; Sasaki, Masao;
(Shimada-shi, JP) |
Correspondence
Address: |
DARBY & DARBY P.C.
805 Third Avenue
New York
NY
10022
US
|
Family ID: |
43333340 |
Appl. No.: |
10/215740 |
Filed: |
August 9, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10215740 |
Aug 9, 2002 |
|
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PCT/JP01/06926 |
Aug 10, 2001 |
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Current U.S.
Class: |
5/652 ;
5/655.5 |
Current CPC
Class: |
B29L 2031/751 20130101;
A47C 27/001 20130101; A47C 27/053 20130101; A47C 21/046 20130101;
B29C 45/2628 20130101; A47C 27/144 20130101; A47C 27/20 20130101;
A47C 27/087 20130101; A47C 27/081 20130101; B29C 33/0033 20130101;
B29K 2009/06 20130101; A47C 27/148 20130101 |
Class at
Publication: |
5/652 ;
5/655.5 |
International
Class: |
A47C 027/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 18, 2002 |
JP |
2002-9390 |
Claims
What is claimed is: Claims of an invention of the present
application are as described below.
1. A bed cushion with thin and vertical diaphragms to be buckled
when pressed arranged in a lattice, characterized in that said
diaphragms are made of elastomer having Shore A hardness of 20 to
40.
2. The bed cushion according to claim 1, characterized in that the
lattice is in a square shape, a length to width ratio thereof being
substantially identical to a length to width ratio of a bed.
3. The bed cushion according to claim 1, characterized in that the
elastomer forming the diaphragm is styrene based elastomer.
4. The bed cushion according to claim 2, characterized in that the
elastomer forming the diaphragm is styrene based elastomer.
5. A bed characterized in that the bed cushion according to claim 1
is placed in a fixing frame in which said cushion is fitted, an
upper edge of said cushion being coupled to an upper edge of the
fixing frame.
6. A bed characterized in that the bed cushion according to claim 2
is placed in a fixing frame in which said cushion is fitted, an
upper edge of said cushion being coupled to an upper edge of the
fixing frame.
7. A bed characterized in that the bed cushion according to claim 3
is placed in a fixing frame in which said cushion is fitted, an
upper edge of said cushion being coupled to an upper edge of the
fixing frame.
8. A mold for a cushion, characterized in that a mold for a cushion
with thin diaphragms arranged in a lattice on plan view comprises a
first mold and a second mold, said first mold having a
predetermined number of first protrusions provided in a standing
manner in substantially square prisms and insertion spaces formed
between the first protrusions, the first protrusions and the
insertions spaces being alternately arranged like a checkerboard in
one plane, while the second mold, in a fitted state to said first
mold, having insertion spaces in which the respective first
protrusions of the first mold are inserted with gaps to be cavities
for forming diaphragms left, and second protrusions to be inserted
in the insertion spaces of said first mold with predetermined gaps
left, the second protrusions and said insertions spaces being
alternately arranged like a checkerboard in one plane, a side
surface of each of the first protrusions of said first mold and a
side surface of each of the second protrusions of the second mold
being provided with substantially identical drawing gradients, a
gap to be a cavity for forming the diaphragm is secured between the
side surfaces of the first protrusion and the second protrusion in
a fitted state, comers at a base of each first protrusion provided
in said first mold being chamfered to form chamfered portions,
simultaneously therewith, chamfered portions being respectively
formed on comers at a base of each second protrusion provided in
said second mold, in a fitted state, a gap to be a cavity for
forming the diaphragm being formed around each tip of said first
protrusion and second protrusion, a gap to be a cavity for forming
a communication diaphragm that provides communication between
comers of the gap being formed between the chamfered portions of
said first protrusion and second protrusion, and in a fitted state
of the first and second molds, an outer frame surrounding four
peripheral surfaces thereof with a gap to be a cavity left.
9. The bed cushion having thin and vertical diaphragms to be
buckled when pressed arranged in a lattice, characterized in that
said diaphragms are made of elastomer having Shore A hardness of 20
to 40, and a resilience reinforcing agent is mixed into said
elastomer.
10. The bed cushion according to claim 8, characterized in that
said resilience reinforcing agent is hydrozincite.
11. The bed cushion according to claim 10, characterized in that
said diaphragm is made of elastomer and contains lubricant of 0.3
to 10 parts by weight with respect to said elastomer of 100 parts
by weight.
12. The cushion according to claim 8, characterized in that the
lubricant is fatty acid based lubricant.
13. The cushion according to claim 9 characterized in that the
cushion body formed by said mold for a cushion is made of gel
consisting of elastomer to which a softener is added.
14. A cushion made of elastomer integrally formed with elastic thin
diaphragms arranged in a lattice on plan view, characterized in
that an air vent is provided in a predetermined position of said
diaphragm.
15. The cushion according to claim 14, characterized in that said
diaphragm has a section tapered from a lower portion to an upper
portion.
16. The cushion according to claim 14, characterized in that the
air vent is provided at a height ranging from 60% to 80% of a
height of the diaphragm.
17. The cushion according to claim 15, characterized in that the
air vent is provided at a height ranging from 60% to 80% of a
height of the diaphragm
18. A mold for a cushion, characterized in that a mold for a
cushion with thin diaphragms arranged in a lattice on plan view
comprises a first mold, a second mold, and an outer frame, said
second mold having a predetermined number of protrusions provided
in a standing manner in substantially square prisms, and having, in
insertion spaces formed between the protrusions, space keeping
protrusions formed in a protruding manner at a predetermined
height, the space keeping protrusions and said protrusions being
alternately arranged like a checkerboard in one plane, the first
mold having inserting portions in which the respective protrusions
of the second mold being inserted with gaps to be cavities for
forming the diaphragms left, and middle protrusions to be inserted
in the insertion spaces of the second mold and, with gaps to be
cavities for forming the diaphragms left, to be abutted against
protrusion end surfaces of the space keeping protrusions in the
insertion spaces with shapes thereof matched, alternately arranged
like a checkerboard in one plane, and an outer frame surrounding
four peripheral surfaces thereof with gaps to be cavities left.
19. A cushion made of elastomer integrally formed with elastic thin
diaphragms arranged in a lattice on plan view, characterized in
that an upper edge of said diaphragm is thinner than a lower edge
of said diaphragm.
20. The cushion according to claim 19, characterized in that said
diaphragm has a tapered section near the upper edge.
21. The cushion according to claim 19, characterized in that the
diaphragm has a gradually tapered section.
22. A cushion with thin and vertical diaphragms to be buckled when
pressed arranged in a lattice, characterized in that said diaphragm
is made of elastomer and contains lubricant of 0.3 to 10 parts by
weight with respect to said elastomer of 100 parts by weight.
23. The cushion according to claim 22, characterized in that the
lubricant is fatty acid based lubricant.
24. The cushion according to claim 22, characterized in that the
elastomer forming the diaphragm further contains filler.
25. The cushion according to claim 23, characterized in that the
elastomer forming the diaphragm further contains filler
26. The cushion according to claim 22, characterized in that the
elastomer forming the diaphragm contains a filler, and is low
expansion elastomer with an expansion ratio of 1.01 to 2.
27. The cushion according to claim 23, characterized in that the
elastomer forming the diaphragm contains a filler, and is low
expansion elastomer with an expansion ratio of 1.01 to 2.
28. The cushion according to claim 22, characterized in that the
elastomer forming the diaphragm is polystyrene based elastomer.
29. The cushion according to claim 22, characterized in that the
elastomer forming the diaphragm is elastomer into which acrylic
soft resin is mixed.
30. The cushion according to claim 22, characterized in that powder
is attached to the elastomer forming the diaphragm.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of International
Application No. PCT/JP01/06926 filed Aug. 10, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention of the present application relates to a
cushion made of elastomer and a bed using the same.
[0004] The invention of the present application relates to a bed
cushion made of elastomer and a bed using the same, and more
particularly to a cushion with thin diaphragms arranged in a
lattice.
[0005] The invention of the present application relates to a
cushion made of elastomer that is used for a bed for preventing
bedsore, a normal bed, a chair, a sofa, or the like and exhibits a
satisfactory property.
[0006] The invention of the present application relates to a mold
for forming a cushion used for a bed for preventing bedsore, a
normal bed, a chair, a sofa, or the like.
[0007] 2. Description of the Related Art
[0008] Bed cushions are required to have comfortableness during
sleep as well as a function of supporting and holding a weight of a
human. Specifically, the cushions are required to have appropriate
softness, compressibility, high vibration absorption, deformation
compliance, and no flattening. In the past, cotton, web of
synthetic short fiber, synthetic resin foam such as polyurethane,
coil springs, or the like has been used alone or in
combination.
[0009] Attention is also directed to shapes of bed cushions, and a
known bed cushion has, for example, an uneven surface, or thin and
vertical diaphragms arranged in a lattice. A known bed cushion with
thin and vertical diaphragms arranged in a lattice, for example,
has the diaphragms made of sponge rubber, semirigid materials, or
gel materials (Japanese Utility Model Laid-Open No. 52-15307, U.S.
Pat. No. 5,749,111 specification). The diaphragm made of sponge
rubber provides cushioning by compression of the sponge rubber of
the diaphragm, which is likely to cause, so called, a feeling of
touching a bottom.
[0010] The cushion with the diaphragms made of semirigid materials
provides cushioning by tilting the diaphragms toward a side, and
thus there are disadvantages of lacking softness when a user lies
thereon and inferiority in soft absorption of light load.
Especially, there is hardness in bounce which the user feels when
the user's body touches the diaphragms forming the cushion to start
to be compressed.
[0011] The diaphragm made of gel materials provides cushioning by
bending the gel materials of the diaphragm and has good cushioning,
but has a problem of lacking durability such as early occurrence
of, so called, flattening because it is the gel material.
[0012] As described above, for forming the cushion with thin and
vertical diaphragms arranged in a lattice on plan view, a molds is
required that configures gaps (cavities) for forming thin
diaphragms in a lattice on plan view when the mold is fitted.
[0013] A mold N100a for forming the above described cushion has
diaphragms Nb formed in a lattice on plan view by forming
protrusions N102 in substantially square prisms arranged vertically
and horizontally in a protruding manner from a substrate N101, and
filling resin such as semirigid materials in gaps (cavities) N102a
formed between the protrusions N102 to thereby (FIG. 27).
[0014] As a mold for forming a similar cushion, there is a mold
N100b constituted by a lower mold N100b1 and an upper mold N100b2
as shown in FIG. 28.
[0015] The lower mold N100b1 has a predetermined number of
protrusions N103 formed into substantially square prisms and
provided in a standing manner and insertion spaces N104 to be
formed in the protrusions N103, alternately arranged in one plane
formed by a substrate N109.
[0016] The upper mold N100b2 has protrusions N105 in substantially
square prisms to be inserted in the respective insertion spaces
N104 of the lower mold N100b1 with gaps N107 to be cavities for
forming diaphragms Nb of the cushion left, and insertion spaces
N106 in which the respective protrusions N103 of the lower mold
N100b1 are inserted to form the gaps N107 to be cavities,
alternately arranged in one plane formed by a substrate N110. Then,
the lower molds N100b1 and upper N100b2 are fitted, and, with
peripheries thereof surrounded by a frame mold N100c, resin such as
semirigid materials is filled into the gaps N107 formed between the
molds N100b, N100b2 to form the diaphragms Nb.
[0017] As described above, when forming the cushion with the
diaphragms in a lattice on plan view using soft resin materials
such as semirigid materials by the lower molds N100a, upper molds
N100b, a product can be relatively easily removed from the molds
after forming the cushion because of high removability of the
product.
[0018] This cushion is a cushion having a structure where thin and
vertical diaphragms are arranged in a lattice on plan view as
described above, and causes no feeling of touching a bottom in use
and can maintain high absorption for a long time by forming the
diaphragms using elastomer such as thermoplastic elastomer or
rubber.
[0019] This cushion is formed by the mold using elastomer having a
relatively sticky surface such as styrene based thermoplastic
elastomer, or polyolefin based thermoplastic elastomer. Therefore,
when a product is removed from the mold after forming, the sticky
surface of the product sometimes attaches cavity surfaces or comers
in the cavity of the mold (blocking). In this case, there are
problems that removal from the mold takes time to prevent smooth
removal operation of the product, and that a stripping trace caused
by forceful removal remains on a surface of the cushion subjected
to serious blocking.
[0020] The object is to provide a mold from which a product can be
easily and neatly removed by effectively reducing stick or blocking
caused when removing the cushion that is formed using sticky
elastomer in forming as described above from the mold.
[0021] The cushion PD has high absorption. However, when load is
applied by contact with the user, the diaphragms formed in a
lattice are appropriately bent and buckled to thereby achieve
absorption, so that openings of the lattice that receives the
user's body are sometimes blocked by the body of the user PA (FIG.
29).
[0022] This often happens when the user rolls over, and air in the
lattice blocked by a weight of the user is compressed and jetted
from a gap generated between the opening and the user's body,
sometimes hissing. This noise is relatively small, but may annoy a
sick user. Further, the cushion configured as described above
provides satisfactory cushioning, but compared with a cushion
containing liquid or gel materials such as a water bed, a feeling
of touch which a user feels when touching it is different, and a
soft feeling of touch like the water bed cannot be achieved.
[0023] Further, four diaphragms are concentrated to form a cross at
a crossing portion of the respective diaphragms arranged in a
lattice. This compromises flexibility at a center of each crossing
portion of the cushion and generates bounce like partial
protrusions, and sometimes gives an uncomfortable feeling to a user
when he lies on a contact surface of the cushion.
[0024] This cushion is a cushion having a structure where thin and
vertical diaphragms are arranged in a lattice on plan view as
described above, and causes no feeling of touching a bottom in use
and can maintain high absorption for a long time by forming the
diaphragms using elastomer such as thermoplastic elastomer or
rubber.
[0025] The above described cushion has high absorption, but when
the diaphragms having received load are buckled to thereby achieve
absorption, and thus, compared with a cushion containing liquid or
gel materials such as a water bed, an initial feeling of touch
which a user feels when he lies thereon is different, and a soft
feeling of touch like the water bed cannot be achieved.
SUMMARY OF THE INVENTION
[0026] An invention of the present application relates to a cushion
made of elastomer.
[0027] From a study of noise (noise generation) generated when
stress is applied on or removed from a cushion formed from the
elastomer into a specific shape, the inventors have found that the
noise generation mainly occurs when the stress is applied on the
cushion to cause the diaphragms to be buckled and attached to each
other, when the applied stress is removed to cause the diaphragms
to be separated from each other, or when the attached diaphragms
rub against each other, and from a study of prevention of the noise
generation, the inventors have found that it can be achieved by
mixing a large amount of lubricant into the elastomer forming the
diaphragm, mixing filler, or low expansion, thereby completing the
present invention.
[0028] Specifically, the present invention is directed to a cushion
with thin and vertical diaphragms to be buckled when pressed
arranged in a lattice, characterized in that the diaphragm is made
of elastomer and contains lubricant of 0.3 to 10 parts by weight
with respect to the elastomer of 100 parts by weight. The lubricant
is preferably fatty acid based lubricant. The elastomer forming the
diaphragm preferably further contains filler. The elastomer forming
the diaphragm is preferably low expansion elastomer with an
expansion ratio of 1.01 to 2. The elastomer forming the diaphragm
preferably has Shore A hardness of 20 to 40. The elastomer forming
the diaphragm is preferably polystyrene based thermoplastic
elastomer. The elastomer forming the diaphragm is preferably
elastomer into which acrylic soft resin is mixed. Powder is
preferably attached to the elastomer forming the diaphragm. The
present invention is also directed to a bed using the above
described cushion.
[0029] A first invention of the present application is directed to
a bed cushion with thin and vertical diaphragms to be buckled when
pressed arranged in a lattice, characterized in that the diaphragms
are made of elastomer having Shore A hardness of 20 to 40. The
lattice is preferably in a square shape, a length to width ratio
thereof being substantially identical to a length to width ratio of
a bed. The elastomer of the diaphragm is preferably styrene based
thermoplastic elastomer.
[0030] The present invention is also directed to a bed
characterized in that the bed cushion is placed in a fixing frame
in which the cushion is fitted, an upper edge of the cushion being
coupled to an upper edge of the fixing frame.
[0031] A cushion according to the invention of the present
application is a cushion made of elastomer integrally formed with
elastic thin diaphragms arranged in a lattice on plan view,
characterized in that an air vent is provided in a predetermined
position of the diaphragm.
[0032] Specifically, the elastic thin diaphragms are arranged in a
lattice on plan view to thereby form an integrally structured
cushion, and the diaphragms are elastically buckled to achieve
satisfactory cushioning.
[0033] Also, the air vent is provided in an appropriate area of the
diaphragm, so that when the diaphragm is buckled with the opening
of the lattice blocked by the user's body, air in the lattice is
flown out into an adjacent lattice through the air vent. Therefore,
even if the inside of the diaphragm is compressed by rolling over
of the user, drastic injection of a large amount of air from the
opening to generate injection noise is prevented.
[0034] Further, providing the air vent in the appropriate position
of the diaphragm as described above allows the air vent to change a
deformation property of the diaphragm to be flexible.
[0035] A cushion according to the invention of the present
application includes elastic thin diaphragms, each diaphragm being
thinner at its upper edge than its lower edge, thereby providing
flexible deformation like a tip of a brush at the upper edge of
each diaphragm to be a contact surface of the cushion.
[0036] The invention of the present application is directed to a
mold for a cushion, characterized in that it includes a first mold,
a second mold, and an outer frame that form a cushion with thin and
vertical diaphragms arranged in a lattice on plan view.
[0037] The first mold is formed with a predetermined number of
substantially prism-like first protrusions provided in a standing
manner on a plane of a mold substrate. Insertion spaces in which
second protrusions of the second mold are inserted are formed
between the first protrusions. The second mold is formed with a
predetermined number of substantially prism-like second protrusions
provided in a standing manner on a plane of a mold substrate, and
insertion spaces in which the first protrusions of the first mold
are inserted are formed between the second protrusions.
[0038] The first protrusions of the first mold and the insertion
spaces, and the second protrusions of the second mold and the
insertion spaces, respectively are alternately arranged like a
checkerboard in one plane of the mold substrate, and when the molds
are fitted, each of the protrusions is inserted in the other of the
insertion spaces with a gap to be a cavity for forming the
diaphragm being left.
[0039] As described above, a side surface of each of the
substantially prism-like first protrusions of the first mold and a
side surface of each of the substantially prism-like second
protrusions of the second mold are provided with drawing gradients
of the same angle to be tapered in such a manner that a square on
an end surface at a protruding tip becomes somewhat smaller.
Therefore, when the first mold and the second molds are fitted, the
protrusions of the first mold are inserted in the insertion spaces
of the second mold, and the protrusions of the second mold are
inserted in the insertion spaces of the first mold.
[0040] In a fitted state of the first and second molds, an outer
frame is fitted to surround four peripheral surfaces thereof.
[0041] Thus, a gap (cavity) for forming a side wall to be a
peripheral frame of the cushion is formed between the peripheries
of the fitted first and second molds and an inner surfaces of the
outer frame, and in a fully fitted state of the molds, cavities for
forming the diaphragms of the cushion are formed in a lattice on
plan view in each mold.
[0042] In the cavities of the molds for a cushion fitted as
described above, a semirigid material such as thermoplastic
elastomer is filled. Thus, the cushion with relatively thin
diaphragms arranged in a lattice on plan view can be formed in the
cavity.
[0043] A mold according to the invention of the present application
includes a first mold, a second mold, and an outer frame. The
second mold is formed with a predetermined number of substantially
prism-like protrusions provided in a standing manner on a plane of
a mold substrate, and insertion spaces are formed between the
respective protrusions. Insertion spaces are formed between the
respective projections. In the insertion spaces, space keeping
protrusions lower than the protrusions are formed. The space
keeping protrusions and the protrusions are alternately arranged
like a checkerboard in one plane.
[0044] The first mold is formed with inserting portions in which
the respective protrusions of the second mold are inserted. Between
the respective inserting portions, middle protrusions to be abutted
against protrusion end surfaces of the space keeping protrusions
formed in the insertion spaces of the second mold are formed in a
protruding manner. The middle protrusions and the inserting
portions are alternately arranged like a checkerboard in one plane
such as a mold substrate.
[0045] Thus, in a fitted state of the first and second molds, each
of the protrusions of the second mold is inserted in the inserting
portion of the first mold. Simultaneously therewith, each middle
protrusion of the first mold is inserted in the insertion space of
the second mold, and abuts against the end surface of the space
keeping protrusion that protrudes in the insertion space to form an
identical contour to each protrusion of the second mold.
[0046] In the fitted state, a gap to be a cavity for forming the
diaphragm of the cushion is formed between each protrusion of the
second mold and the middle protrusion and space keeping protrusion
of the first mold in a coupled state.
[0047] As described above, in the fitted state of the first and
second molds, an outer frame is fitted to surround four peripheral
surfaces thereof. Thus, a gap for forming a diaphragm to be a
peripheral frame of the cushion is formed between the four
peripheral surfaces of the fitted first and second molds and an
inner surface of the outer frame.
[0048] In the cavities of the molds for a cushion fitted as
described above, thermoplastic elastomer is filled. Thus, the
cushion with relatively thin diaphragms arranged in a lattice on
plan view can be formed in the cavity.
[0049] As described above, dismantling the outer frame and the
first and second molds causes the cushion made of thermoplastic
elastomer formed in the mold to remain in the second mold having
high adhesion. That is, the cushion formed in a lattice remains
fitted in the gaps between the middle protrusions.
[0050] For the above described cushion, a portion of the space
keeping protrusion having abutted against the end surface of the
middle protrusion is removed to be opened with the second mold
removed. Therefore, in removal operation of the product, a worker
can take out the cushion remaining in the first mold easily and
neatly by drawing with picking an opening edge and striping a wall
of the product from the surface of the mold.
[0051] The invention of the present application is also directed to
a bed that uses the above described cushion laid on a spring unit
including springs connected in parallel, each spring including
large numbers of coil springs connected in parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] FIG. 1 is a perspective view of a bed cushion that embodies
the present invention;
[0053] FIG. 2 is an exploded view of a mold for a cushion and a
product according to a second invention of the present
application;
[0054] FIG. 3 is a perspective view, partly omitted, of a first
mold and a second mold of the present invention;
[0055] FIG. 4 is a perspective view, partly notched, of the cushion
molded be the molds of FIG. 3;
[0056] FIG. 5 is a plan view of a comer of the cushion of FIG.
4;
[0057] FIG. 6 is a sectional view along the line V-V of FIG. 5;
[0058] FIG. 7 is a vertical sectional view of a dismantled
mold;
[0059] FIG. 8 is a vertical sectional view of the first and second
molds and an outer frame being fitted;
[0060] FIG. 9 is a vertical sectional view of elastomer being
injected into a cavity by the mold and then the mold being
dismantled to remove the product from the mold;
[0061] FIG. 10 is a perspective view of a bed with the cushions
vertically and horizontally arranged;
[0062] FIG. 11 is a perspective view, partly notched, of a cushion
with an air vent provided in a diaphragm according to another
embodiment of the invention of the present application;
[0063] FIG. 12 is a sectional view along the line II-II of FIG.
11;
[0064] FIG. 13 is a vertical sectional view of the cushion on which
a user's weight is applied, with an air vent provided in a
diaphragm;
[0065] FIG. 14 is a perspective view, partly notched, of a bed
cushion with a frame body provided around a cushion body for a bed
integrally formed with the cushions vertically and horizontally
arranged;
[0066] FIG. 15 is a vertical sectional view of cushions with two
air vents;
[0067] FIG. 16 is a perspective view, partly omitted, of a first
mold and a second mold according to another embodiment the
invention of the present application;
[0068] FIG. 17 is an exploded view of a mold for a cushion
according to the invention of the present application;
[0069] FIG. 18 is a vertical sectional view of the mold of FIG. 17
being fitted;
[0070] FIG. 19 is a vertical sectional view of the mold being
opened;
[0071] FIG. 20 is a vertical sectional view of a cushion formed by
the mold;
[0072] FIG. 21 is a perspective view of a cushion material for a
bed being configured with the cushion materials vertically and
horizontally arranged;
[0073] FIG. 22 is a vertical sectional view of deformation of a
diaphragm when load is applied on the cushion;
[0074] FIG. 23 is a vertical sectional view of a cushion having a
diaphragm with a tapered upper edge;
[0075] FIG. 24 is a vertical sectional view of an upper edge of the
cushion having a diaphragm with a tapered upper edge being
bent;
[0076] FIG. 25 is a vertical sectional view of a cushion having a
diaphragm with a stepwise tapered upper edge;
[0077] FIG. 26 is a vertical sectional view of load being applied
on a bed cushion;
[0078] FIG. 27 is a vertical sectional view of a conventional mold
for a cushion being dismantled;
[0079] FIG. 28 is a vertical sectional view of a conventional mold
for a cushion provided with protrusions on both of an upper mold
and a lower mold being dismantled; and
[0080] FIG. 29 is a vertical sectional view of a conventional
cushion on which a user's weight is applied to generate injection
noise.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0081] Next, a first invention of the present application will be
described.
[0082] FIG. 1 is a schematic perspective view of a bed cushion
according to the invention. The whole thereof is made of elastomer.
Reference numeral 1 denotes a vertical side wall of the bed
cushion, and reference numeral 2 denotes a horizontal side wall of
the bed cushion. Reference numeral 3 denotes a vertically arranged
diaphragm, and reference numeral 4 denotes a horizontally arranged
diaphragm.
[0083] The diaphragm 3 and diaphragm 4 form a lattice. When
pressed, that is, when load is applied, the diaphragms of the
pressed portion are buckled to act as a cushion. Thermoplastic
elastomer used in the present invention includes thermoplastic
elastomer or rubber. The thermoplastic elastomer is a material that
behaves as a rubber-like elastic body at room temperatures, and
whose composition is deformed due to an increase in temperature.
The thermoplastic elastomer includes polystyrene based
thermoplastic elastomer, polyolefin based thermoplastic elastomer,
polyvinyl chloride based thermoplastic elastomer, polyester based
thermoplastic elastomer, polyurethane based thermoplastic
elastomer, polyamide based thermoplastic elastomer,
1,2-polybutadiene based thermoplastic elastomer, fluororubber based
thermoplastic elastomer, chlorinated polyethylene based
thermoplastic elastomer, dynamic cross-linked thermoplastic
elastomer, or the like.
[0084] The polystyrene based thermoplastic elastomer is a block
copolymer using polystyrene as a hard segment in a molecule, and
using polydiene such as polygutadiene or polyisoprene as a soft
segment. For example, a styrene-butadiene-styrene block copolymer
(SBS), styrene-isoprene-styrene block copolymer (SIS),
styrene-ethylene butylene-styrene block copolymer (SEBS),
styrene-ethylene propylene-styrene block copolymer (SEPS), or the
like are included, and mixture of hydrogenated styrene-butadiene
block copolymer and polypropylene are also included.
[0085] Used as the polyolefin based thermoplastic elastomer are a
mechanical blend of olefin based rubber such as EPDM or
isobutylene-isoprene rubber or polyolefin based rubber (a blend
type), a blend of the olefin based rubber and polyolefin resin
mixed in the presence of organic peroxide to have a rubber phase
partially cross-linked (a partial cross-linked blend type), a
complex containing polypropylene as a continuous phase and
cross-linked EPDM as a disperse phase (a complete cross-linked
blend type), or the like.
[0086] The polyvinyl chloride based thermoplastic elastomer
includes a blend of polyvinyl chloride and nitrile rubber or
partially cross-linked nitrile rubber, or the like.
[0087] The polyester based thermoplastic elastomer includes, for
example, a polyester polyether type elastomer produced by ester
interchange and polycondensation with dimethyl terephthalate,
1,4butanediol and polytetramethylene ether glycol as raw material,
and polyester polyester type elastomer produced by ester
interchange and ring-opening reaction with dimethyl terephthalate,
1,4butanediol and .epsilon.-caprolactone as raw materials. The
polyurethane based thermoplastic elastomer includes elastomer with
a hard segment and soft segment formed by reacting long-chain diol
and short-chain diol having terminal active hydrogen and
diisocyanate.
[0088] The polyamide based thermoplastic elastomer includes, for
example, elastomer produced by ring-opening reaction and
condensation with lauryl lactam, dicarboxylic acid, and polyether
diol as raw materials.
[0089] Used as rubber is natural rubber or synthetic rubber. The
synthetic rubber includes polybutadiene rubber, polychloroprene
rubber, polyisoprene rubber, butadiene acrylonitrile rubber,
isobutylene isoprene rubber, or the like.
[0090] For the elastomer used in the present invention, the
polystyrene based thermoplastic elastomer is especially preferably
used because of its high flexibility and durability. The elastomer
used in the present invention has Shore A hardness of 20 to 40,
preferably 25 to 35. When the elastomer having the above described
hardness is used for diaphragms for a bed cushion having a
structure where thin and vertical diaphragms are arranged in a
lattice, the diaphragms are buckled when load is applied to thereby
provide a cushion that causes no feeling of touching a bottom, and
that has flexibility, high absorption of light load and high
durability.
[0091] The cushion having the diaphragm made of the elastomer as
described above has a problem of noise generated every time a user
rolls over for the above described reason when used for a bed for
example, but this problem can be solved by mixing lubricant into
the elastomer, and removability in forming can be improved. The
lubricant includes hydrocarbon based lubricant such as paraffin
wax, microwax, or polyethylene wax; fatty acid based lubricant such
as stearic acid, behenic acid, or 12-hydroxystearic acid; higher
alcohol based lubricant such as stearyl alcohol, or cetyl alcohol;
amide based lubricant such as stearic acid amide, erucic acid
amide, oleic acid amide, methylene bis stearic acid amide, ethylene
bis oleic acid amid; ester based lubricant such as cetyl palmitate,
stearyl stearate, butyl stearate, or stearic acid monoglyceride,
pentaerythritol tetrastearate; metallic soap based lubricant such
as lead stearate, zinc stearate, calcium stearate, magnesium
stearate. Among them, the fatty acid based lubricant produces a
preferable effect. A larger amount of lubricant has to be mixed
than in usual use, and the amount is 0.3 to 10 parts by weight,
preferably 0.5 to 5 parts by weight with respect to elastomer of
100 parts by weight.
[0092] Further mixing filler into the elastomer forming the
diaphragm of the cushion of the present invention of the
application can reduce elasticity of the diaphragm, thereby
improving prevention of noise generation. Mixing the filler also
improves removability in forming. Preferable filler is mineral
filler. For example, powdered filler such as calcium carbonate,
barium sulfate, talc, quartz powder, or silica; balloon filler such
as glass balloons or Shirasu balloon; fiber filler such as glass
fiber, or mineral fiber. Among them, calcium carbonate, resin
coated calcium carbonate (for example, Calpet: trade name of resin
coated calcium carbonate manufactured by NITTO FUNKA KOGYO K.K.),
and glass balloon (for example, Scotch Light: trade name of a
minute hollow glass balloon manufactured by SUMITOMO 3M Limited)
are preferably used. The mixing amount of the filler is 0.5 to 30
parts by weight, preferably 1 to 10 parts by weight with respect to
elastomer of 100 parts by weight.
[0093] Mixing acrylic soft resin into the elastomer forming the
diaphragm of the cushion according to the present invention can
soften the elastomer to improve prevention of noise generation. The
acrylic soft resin is resin that presents flexibility like soft
polyvinyl chloride at room temperature. A preferable acrylic soft
resin is a polymer of a multilayer structure, that is, a polymer in
which two or more kinds of acrylic polymers form a core shell type
multilayer structure. Such acrylic soft resin presents satisfactory
flexibility at room temperature, has durability to bending, and is
superior in transparency and weather resistance.
[0094] The core shell type acrylic polymer is a core shell acrylic
polymer including, as a core, a polymer made by emulsion
polymerization of a crosslinking agent such as butyl acrylate
monomer or a mixture of butyl acrylate monomer and 2-ethylhexyl
acrylate, (meta) acrylic ester having alkyl groups of carbon
numbers 1 to 4, vinyl cyanide, maleic acid mono alkyl ester, or
diacrylate or divinyl benzene of polyalcohol, and including, as a
shell, a polymer made by polymerization of aromatic vinyls, vinyl
cyanide, and crosslinking agent.
[0095] Another example of acrylic soft resin will be shown. It is a
multilayer structure polymer made by combination of 10 to 90 parts
by weight of a polymer layer [A] with at least one layer made by
polymerization of monomer mixture, at Tg temperature of 30.degree.
C. or less, consisting of 30 to 99.9% by weight of at least a kind
of acrylic acid alkyl ester having alkyl groups of carbon numbers 1
to 12, 0 to 70% by weight of at least a kind of methacrylic acid
alkyl ester having alkyl groups of carbon numbers 1 to 8, 0 to 30%
by weight of copolymerizable unsaturated monomer, 0.1 to 10% by
weight of polyfunctional crosslinkable monomer and/or
polyfunctional graft monomer, with 90 to 100 parts by weight of a
polymer layer [B] with at least one layer made by polymerization of
monomer mixture, at Tg temperature of -20.degree. to 50.degree. C.,
consisting of 30 to 99.9% by weight of at least a kind of acrylic
acid alkyl ester having alkyl groups of carbon numbers 1 to 12, 1
to 70% by weight of at least a kind of methacrylic acid alkyl ester
having alkyl groups of carbon numbers 1 to 8, 0 to 30% by weight of
copolymerizable unsaturated monomer, and is acrylic soft multilayer
structure resin whose outermost layer is the polymer layer [B].
[0096] Another example of acrylic soft resin will be shown. It is
acrylic soft multilayer structure resin consisting of 30 to 80
parts by weight of a rubber layer obtained by polymerization of 60
to 99.5% by weight of acrylic acid alkyl ester having alkyl groups
of carbon numbers 1 to 8, 0 to 39.5% by weight of monofunctional
monomer having one copolymerizable vinyl group, 0.5 to 5% by weight
of polyfunctional monomer having at least two vinyl groups or
vinyliden groups, and 20 to 70 parts by weight of a hard resin
layer obtained by polymerization of 40 to 100% by weight of
meta-acrylic acid methyl, 0 to 60% by weight of acrylic acid alkyl
ester having alkyl groups of carbon numbers 1 to 8, and 0 to 20% by
weight of a monomer having a copolymerizable vinyl group or
vinyliden group, and whose outermost layer is a hard resin
layer.
[0097] Another example of acrylic soft resin will be shown. It is
acrylic soft multilayer structure resin consisting of (A) 5 to 30
parts by weight of an innermost hard polymer layer made by
polymerization of monomer mixture consisting of 80 to 98.99% by
weight of methyl methacrylate, 1 to 20 % by weight of acrylic acid
alkyl ester having alkyl groups of carbon numbers 1 to 8, 0.01 to
1% by weight of polyfunctional graft agent, and 0 to 0.5% by weight
of polyfunctional crosslinking agent; (B) 20 to 45 parts by weight
of a middle hard polymer layer made by polymerization of monomer
mixture consisting of 70 to 99.5% by weight of acrylic acid alkyl
ester having alkyl groups of carbon numbers 1 to 8, 0 to 30% by
weight of methyl methacrylate, 0.5 to 5% by weight of
polyfunctional graft agent, and 0 to 5% by weight of polyfunctional
crosslinking agent; (C) 50 to 75 parts by weight of an outermost
hard polymer layer made by polymerization of monomer mixture
consisting of 90 to 99% by weight of methyl methacrylate, 10 to 1%
by weight of acrylic acid alkyl ester having alkyl groups of carbon
numbers 1 to 8; and having an average particle size of 0.01 to 0.3
.mu.m.
[0098] This acrylic soft resin especially produces a preferable
effect when mixed into polystyrene based thermoplastic elastomer.
An amount of mixture of the acrylic soft resin into the elastomer
is 0.5 to 10 parts by weight with respect to 100 parts by weight of
the elastomer.
[0099] Antioxidant is preferably mixed into the elastomer. Used as
antioxidant is phenolic antioxidant, thioether based antioxidant,
phosphoric acid based antioxidant, and the most preferable is the
phenolic antioxidant. The phenolic antioxidant includes
2,6-di-t-butyl-4-methylphenol, n-octadecyl-3-(3',
5'-di-t-butyl-4'-hydrox- yphenyl) propionate, triethylene
glycol-bis-[3-(3-t-butyl-4-hydroxy-5-meth- ylphenyl) propionate].
An amount of mixture is 0.3 to 4 parts by weight, preferably 2 to 3
parts by weight, with respect to 100 parts by weight of the
elastomer. Durability is insufficiently improved with the amount of
0.3 parts by weight or less, and the effect is unchanged with the
amount of 4 parts by weight or more.
[0100] The cushion according to the present invention can be used
for a chair, or bed, and a size of the cushion is appropriately
determined in accordance with each use. For example, in a cushion
used for a bed, a lattice of the cushion is formed to have a height
of the diaphragm of 10 to 300 mm, and a width of the diaphragm of
20 to 200 mm. The diaphragms include diaphragms arranged vertically
of the bed, and diaphragms arranged horizontally of the bed, and a
ratio of the width of the diaphragms arranged vertically and the
width of the diaphragms arranged horizontally of the bed is
preferably substantially identical to a length to width ratio the
bed. This improves cushioning during sleep. A thickness of the
diaphragm is 0.5 to 5 mm, preferably 1.5 to 3 mm. Either reducing
the thickness of the diaphragm using harder elastomer, or
increasing the thickness of the diaphragm by using softer elastomer
to the contrary compromises natural cushioning during sleep. For
obtaining soft and natural cushioning without touching the bottom
with respect to a weight of a human body, the hardness of the
elastomer and the thickness of the diaphragm are important factors.
In this view, elastomer having Shore A hardness of 25 to 38 is used
to form a diaphragm having thickness of 1.5 to 3.0 mm.
[0101] Low expansion of the elastomer forming the diaphragm can
increase the effect of preventing noise generation described above.
Expansion ratio is preferably 1.01 to 2. The expansion can be
carried out with an expanding agent in a usual manner. Attaching
powder on a surface of the elastomer forming the diaphragm can also
increase the effect of preventing noise generation. Used as the
powder is starch such as corn starch, flour, or potato, silicone,
silicone coated starch. These are attached by an air spray or the
like.
[0102] In the present invention, a cushion where the thin and
vertical diaphragms made of elastomer are arranged in a lattice is
preferably produced by injection molding of the elastomer. The
cushion according to the present invention can be used for a
pillow, seat (chair), or bed, and a size of the cushion is
appropriately determined in accordance with each use. For example,
the injection molding produces a cushion having a size of 25
cm.times.25 cm. A plurality of the cushions are then joined to have
a predetermined size of the bed for providing a bed cushion. For
joining, the side walls of the respective cushions are coupled. An
adhesive, a wire or stapler are used for coupling, but upper
portions only are preferably coupled so as to prevent an increase
in thickness over the diaphragms at a coupling portion by coupling
the side walls, that have an influence on buckling. The diaphragms
at the coupling portions may be previously formed thinner than
other portions. Blending the thermoplastic elastomer while heating
at a temperature 150.degree. C. or more reduces its Shore A
hardness value. By using this, the Shore A hardness value of the
thermoplastic elastomer can be adjusted. In the above described
injection molding, the thermoplastic elastomer is heated up to
around 200.degree. C. and blended, so that the Shore A hardness
value of raw thermoplastic elastomer is preferably adjusted in
consideration of this point.
[0103] A soft plate may be provided on an upper surface and/or a
lower surface of the bed cushion with thin and vertical diaphragms
of elastomers arranged in a lattice as required. The soft plate is
preferably flexible and transfers load of a human body as it is to
the diaphragms of the cushion. The soft plate is a polyurethane
foam sheet, for example. The entire plate may be covered with a
cloth as required.
[0104] The above described cushion may be used for the bed as it
is, but the bed cushion is preferably placed in a fixing frame in
which the cushion is fitted to form a bed by coupling an upper edge
of the cushion to an upper edge of the fixing frame. They are
coupled by an adhesive, a wire, a stapler, or the like. The fixing
frame may be made of wood, synthetic resin or metal. Coupling the
upper edge of the bed cushion to the upper edge of the fixing frame
causes the bed cushion to be suspended by the fixing frame, thereby
achieving sufficient cushioning by the buckled diaphragms. Such
suspended structure produces tension in a shorter horizontal
direction, but does not produces much tension in a longer vertical
direction than in the horizontal direction. However, substantially
identical tension in the vertical and horizontal directions
provides good cushioning. The tension can be changed by either of
two methods: changing the thickness of the diaphragm; or changing
the width of the diaphragm. Changing the thickness of the diaphragm
causes inconvenience in production, so that changing the width of
the diaphragm for adjustment is preferable. It is described above
from this viewpoint that the ratio of the width of the diaphragms
arranged vertically and the width of the diaphragms arranged
horizontally of the bed is preferably substantially identical to a
length to width ratio of the bed.
[0105] A cushion with the above described shape was injection
molded at resin temperature of 200.degree. C., and removal
temperature of 50.degree. C. using compositions shown in Table 1.
The cushion was sized to have a length of 35 cm and a width of 24
cm with five lattices vertically arranged and five lattices
horizontally arranged, each lattice having a height of the
diaphragm of 150 mm, vertical width of the diagram of 69 mm,
horizontal width of the diagram of 48 mm, and thickness of the
diagram of 2.0 mm. In Table 1, Clayton D1107 (manufactured by
Shell, trade name) represents styrene-isoprene-styrene block
copolymer (15% styrene content, Shore A hardness 37). Calpet M
(manufactured by NITTO FUNKA KOGYO K.K., trade name) represents 20%
resin coated calcium carbonate. Scotch Light K46 (manufactured by
SUMITOMO 3M Limited, trade name) represents a minute hollow glass
balloon. SA-1000-FO (manufactured by KURARAY CO., LTD.) represents
core shell type acrylic soft resin, and AO-60 (Asahi Denka Kogyo
K.K.) represents phenolic antioxidant.
[0106] Five cushions were vertically joined and five cushions are
horizontally joined to create the bed cushion. A polyurethane foam
sheet was disposed on and under the joined material, and then the
entire material was covered with a polyester fiber cloth. Then, the
material was fitted in a wooden fixing frame having inside
dimensions of 173 cm length, 121 cm width, and 20 cm height. The
upper edge of the fixing frame previously had large numbers of
holes drilled. The upper edge of the bed cushion was coupled to the
upper edge of the fixing frame with wires using the holes to create
a bed. A comfortable bed was obtained. A bed similarly created with
powder (manufactured by NIKKA LIMITED, trade name: Nikkariko)
attached to the injection molded cushion by an air spray achieved
improvement in preventing noise generation.
[0107] Removability in injection molding of the cushion, and a
degree of noise generation of the bed created using the cushion in
use (in rolling over) was tested, and the results were collectively
shown in Table 1.
[0108] For evaluation of removability, "Very well" represents
removing from the mold very well, "Well" represents removing from
the mold well, "Not well" represents removing from the mold being a
little difficult, and "Poor" represents removing from the mold
being impossible.
[0109] For evaluation of noise generation, "Very well" represents
not obstructive at all, "Well" represents not obstructive though
there is noise, "Not well" represents a little obstructive, and
"Poor" represents obstructive.
[0110] A bed was similarly created with powder (manufactured by
NIKKA LIMITED, trade name: Nikkariko) attached to the injection
molded cushion by an air spray. Improvement in preventing noise
generation was achieved.
1 TABLE 1 Comparative Specific exampic example 1 2 3 4 5 1 Clayton
D1107 80 100 100 100 100 100 Azodicarboxylic acid 1 -- -- -- 1 --
amide Stearic acid 2 2 2 2 2 0.1 Ethylene bisamide 0.1 0.1 0.1 0.1
0.1 0.1 Calpet M 10 20 -- -- -- -- Scotch Light K46 10 -- 20 -- --
-- SA-1000-F0 20 -- -- 20 -- -- AO-60 2.5 2.5 2.5 2.5 2.5 --
Expansion ratio 1.05 1 1 1 1.05 1.05 Removability Very Well Well
Well Not Poor well well Noise generation in Very Well Well Well Not
Poor rolling over well well
[0111] The cushion according to the present invention has the
diaphragms that are buckled when load is applied, so that it causes
no feeling of touching a bottom, has flexibility, high absorption
of light load and high durability, generates no noise when the load
is applied or removed, and has good removability in forming. This
cushion is suitable for a bed cushion.
[0112] A resilience reinforcing agent is mixed into the elastomer.
The resilience reinforcing agent includes hydrozincite, magnesium
oxide, white carbon, carbon black, clay (kaolin clay, burnt clay,
or the like). Resilience of the elastomer is improved by mixing the
resilience reinforcing agent. The mixing amount of the resilience
reinforcing agent is 2 to 20 parts by weight, preferably 3 to 10
parts by weight with respect to elastomer of 100 parts by weight.
The hydrozincite is the most preferable resilience reinforcing
agent. Calcium carbide cannot be used because of the poor
resilience reinforcing effect thereof, though it is also an
inorganic substance.
[0113] An elastomer composition consisting of compositions shown in
Table 2 was prepared. Clayton D1107 represents
styrene-isoprene-styrene block copolymer (manufactured by Shell,
trade name, 15% styrene content, Shore A hardness 37). AO-60
(manufactured by Asahi Denka Kogyo K.K.) represents phenolic
antioxidant.
[0114] Stearic acid was used as an anti-blocking agent. This
composition was deforming extruded at 200.degree. C. to create a
cushion structure having a length of 35 cm and a width of 24 cm
that includes five lattices vertically arranged and five lattices
horizontally arranged, each lattice having a height of the
diaphragm of 150 mm or 60 mm, a vertical width of the diaphragm of
69 mm, a horizontal width of the diaphragm of 48 mm, and a
thickness of the diaphragm of 2.0 mm. Powder (manufactured by NIKKA
LIMITED, trade name: Nikkariko) was attached to the cushion
structure by an air spray. Shore A hardness of the diaphragm of
this structure was 34. Five structures were vertically joined and
five structures were horizontally joined to create a bed
cushion.
[0115] Operational suitability tests were conducted for a case of
using the bed cushion as it is and a case of using it laid on a 9
cm thick coil spring unit. In the test, for each bed having used
for one month, a trace left on the bed after thirty minutes from
leaving the bed was observed to evaluate resilience. Noise
generation in rolling over for each bed was also evaluated. The
results are collectively shown in Table 2. For evaluation of
resilience, "Very well" represents no trace left, "Well" represents
little trace left, "Not well" represents a little trace left, and
"Poor" represents most of the trace left. For evaluation of noise
generation, "Very well" represents not obstructive at all, "Well"
represents not obstructive though there is noise, "Not well"
represents a little obstructive, and "Poor" represents obstructive
and having a problem.
2 TABLE 2 Test example Comparative example 1 2 3 4 5 6 7 1 2 3 4
Clayton D1107 100 100 100 100 100 100 100 100 100 100 100 Stearic
acid 3 3 3 3 3 3 3 3 3 Process oil 10 Hydrozincite 5 5 2 20 5 5
Magnesium oxide 5 Calcium carbonate 5 AO-60 2 2 2 2 2 2 2 2 2 2 2
Rubber antioxidant 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Pigment 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
Height of lattice-like cushion (cm) 15 6 6 6 6 6 6 6 15 6 6 Spring
mat (cm) No 9 9 9 9 9 9 9 No 9 9 (Results of operational
suitability tests) Flattening (resilience) ; T ; T T ; ; .DELTA. x
x .DELTA. Remarks Somewhat hard Noise generation T T T T T T ; ; ;
x T
[0116] Next, a using manner of the cushion will be described.
[0117] The bed cushion of the present invention of the application
may be used for the bed as it is, but the bed cushion is preferably
placed in a fixing frame in which the cushion is fitted to form a
bed by coupling an upper edge of the cushion to an upper edge of
the fixing frame. They are coupled by an adhesive, a wire, a
stapler, or the like. The fixing frame may be made of wood,
synthetic resin or metal. Coupling the upper edge of the bed
cushion to the upper edge of the fixing frame causes the bed
cushion to be suspended by the fixing frame, thereby achieving
sufficient cushioning by the buckled diaphragms. Such suspended
structure produces tension in a shorter horizontal direction, but
does not produces much tension in a longer vertical direction.
Substantially identical tension in the vertical and horizontal
directions provides good cushioning.
[0118] Next, the cushion according and a manner of using its mold
will be described.
[0119] After the molds are fitted, a material made of thermoplastic
elastomer is charged into the gap to be cavities, and the cavities
are filled therewith. The thermoplastic elastomer is especially
preferable in terms of recyclability and workability. Specifically,
elastomers of styrene base, polyurethane base, polyolefin base,
polyvinyl chloride base, polyester base, or polyamide base, or the
like are used, thereby achieving satisfactory cushioning like a
water bed.
[0120] When a predetermined time passes after a finish of filling
the material, the frame bodies are removed to separate the first
mold (lower mold) and second mold upper mold. At this time, an
article formed in the mold remains in the first mold side having
more protrusions (FIG. 12). The second protrusion of the second
mold is provided with the drawing gradient on the side to thereby
allow the product to be easily stripped from a cavity surface, and
can be neatly drawn from the product.
[0121] Next, a using manner of the cushion with an air vent
provided in a side wall according to the third invention will be
described.
[0122] As described above, the cushion made of the thermoplastic
elastomer formed as described above is used as a cushion for a bed,
chair, sofa, or the like with a cover, and for a large article such
as a bed, as described later, the cushions are vertically and
horizontally arranged to be integrated by adhesion or a stapler for
use as a bed cushion.
[0123] The cushion formed substantially in a lattice on plan view
includes a vertical or horizontal diaphragm or side wall. The
diaphragms or side wall arranged in the lattice are buckled when
the user's weight is applied to function as a cushion with high
elasticity.
[0124] Specifically, the diaphragms or side wall are formed to have
tapered sections so as to be thinner at upper edges than lower
edges of the diaphragms, so that bending of the diaphragms or side
wall to be contact surfaces of the cushion 300B is gradually
reduced from a lower side to the upper edge, and flexible
deformability can be achieved at the upper edge.
[0125] The diaphragms or side wall are elastically deformed
satisfactorily by providing the air vent in a predetermined
position. The air vent is essentially a hole for ventilation inside
the lattice, but concerns an elastic deformation property of the
diaphragms or side wall.
[0126] Injection noise of air occurs partly resulting from the
diaphragms or side wall being drastically bent. As described above,
however, the air vents are provided in the diaphragm or side wall
to thereby soften the areas. That is, when the user's load is
applied, the air vent is deformed to be enlarged or to be an
ellipse, thereby relieving drastic bending caused by the load.
[0127] Thus, for the cushion 300B including the diaphragm or side
wall, the upper edges that are the softest are elastically bent and
deformed to achieve soft feeling of touch in an initial state where
the user 300A touches the contact surface, the diaphragm or side
wall start to be bent from the areas of the air vent as the user's
weight is applied, and a central portion is buckled to be
appropriately elastically deformed. This allows the cushion to
achieve soft cushioning like a tip of a brush without feeling of
touching a bottom or partial protrusions.
[0128] Next, a cushion having partition lines formed therein and a
using manner of its mold will be described.
[0129] With the first mold (lower mold) and second mold (upper
mold) fitted, frame bodies forming an outer frame are abutted
against four peripheral surfaces of the substrates to form an outer
frame of square shape on plan view.
[0130] Accordingly, when the first and second molds, and frame
bodies configured as described above are fitted, a gap for forming
a lattice-like cushion, that is, a cavity is formed between each
coupled article of the middle protrusion of the first mold and the
space keeping protrusion of the second mold and each protrusion
402b of the second mold 402. As described above, after the mold are
fitted, a material made of thermoplastic elastomer is charged into
the cavity, which is filled therewith. Each protrusion of the
second mold is provided with a slight drawing gradient toward a
protruded end so as to facilitate stripping the product formed in
the cavity 404 from a surface of the cavity. Therefore, a drawing
gradient of the protrusion is set in such a manner that the cushion
formed in the cavity 404 remain in the first mold that has
relatively higher adhesion by separation of the first and second
molds and the frame bodies.
[0131] After separation of the mold, a worker removes the cushion
remaining in the first mold. At this time, the cushion remaining in
the first mold is formed with an opening that is formed after
drawing of the space keeping protrusion together with a hollow
portion of a lattice formed by the protrusion of the second
mold.
[0132] In the cushion drawn from the first mold, a partition line
is formed on the diaphragm, the partition line representing a ratio
of a height between the space keeping protrusion of the second mold
and the middle protrusion of the first mold. Thus, the diaphragms
are buckled at the partition line when load of the user is applied
on the cushion, thereby causing no feeling of touching a bottom,
and having flexibility.
[0133] In the present invention, for the bed cushion having a
structure where thin and vertical diaphragms are arranged in a
lattice, the diaphragms are made of elastomer having Shore A
hardness of 20 to 40, so that the diaphragms are buckled when load
is applied, thereby causing no feeling of touching a bottom, and
having flexibility, high absorption of light load. Further, the
resilience reinforcing agent such as hydrozincite is mixed into the
elastomer, so that meritorious effects of high resilience and high
durability to flattening can be achieved.
[0134] Next, embodiments of the invention of the present
application will be described with reference to FIGS. 2 to 10.
[0135] FIG. 2 and FIG. 3 show a mold a for a cushion in a second
example that embodies the present invention.
[0136] A mold 200a includes a first mold 201 to be a lower mold, a
second mold 202 to be an upper mold, and an outer frame mold 203 to
be fitted so as to surround four peripheral surfaces of both the
fitted first and second molds.
[0137] The cushion 200b formed by the mold 200a is integrally
formed using elastomer, thin and horizontal diaphragms 200b1 and
vertical diaphragms 200b2 are arranged in a lattice on plan view,
and peripheries thereof are surrounded by an outer side wall 200b4.
In each lattice, relatively large openings 200e1 and somewhat
smaller openings 200e2 with chamfered comers are arranged like a
checkerboard. Communication diaphragms 200b3 corresponding to the
common chamfered portions provided on edges of the openings e1 are
formed between the common comers of the openings 200e1. The
communication diaphragm 200b3 provides communications between
comers of the diaphragms 200b1, 200b2 surrounding the smaller
openings 200e2.
[0138] The first mold 201 of the mold 200a has a predetermined
number of first protrusions 210 integrally formed vertically and
horizontally in a protruding manner on an upper surface of a
substrate 201a of rectangular shape on plan view through spaces to
be inserting portions 230. The first protrusions 210 and inserting
portions 230 are arranged like a checkerboard on plan view (FIG.
2).
[0139] On the other hand, the second mold 202 has a predetermined
number of second protrusions 220 integrally formed vertically and
horizontally on a lower surface of a substrate 202a through spaces
to be inserting portions 240. The inserting portions 240 and the
second protrusions 220 are arranged like a checkerboard on plan
view like the case of the first mold 201.
[0140] Positional relationship between the first protrusion 210 of
the first mold 201 and inserting portion 230, and positional
relationship between the second protrusion 220 of the second mold
202 and the inserting portion 240 are opposite to each other.
[0141] Thus, when the molds are fitted, each first protrusion 210
of the first mold 201 is inserted in each inserting portion 240 of
the second mold, and simultaneously, each second protrusion 220 of
the second mold 202 is inserted in the inserting portion 230 of the
first mold 201 (FIG. 7).
[0142] The first protrusion 210 of the first mold 201 and the
second protrusion 220 of the second mold 202 are identically
formed. That is, the first protrusion 210 of the first mold 201 is
formed in a protruding manner in a square prism from a surface of
the substrate 201a. The first protrusion 210 is adapted to be
inserted, at its tip surface, in the inserting portion 240 of the
second mold 202 when the molds are fitted in such a manner that the
tip surface abuts against the surface of the substrate 202a of the
second mold 202. Similarly, when the molds are fitted, the second
protrusion 220 of the second mold 202 is inserted in the inserting
portion 230 of the first mold 201 and abuts against the surface of
the substrate 201a (FIG. 8).
[0143] The first protrusion 210 of the first mold has a
predetermined gradient on its side surface, and for example, a
gradient .alpha. 1 of 2.37.degree. in this embodiment, and is
tapered to have somewhat a smaller contour at the tip than a base
of the first protrusion 210. This also applies to the second
protrusion 220, and is tapered toward the tip on side view (FIG.
6).
[0144] Specifically, the first and second protrusions 210, 220 with
gradients are inserted in the inserting portions 230, 240 of the
first and second molds 201, 202 with shapes thereof substantially
matched in a fitted state as shown in FIGS. 7 and 8 to be fitted to
each other with gaps 200g left to be cavities for forming
lattice-like diaphragms 200b1, 200b2 between the first and second
protrusions 210, 220.
[0145] The respective comers at the bases of the first protrusion
210 and second protrusion 220 of the first and second molds 201,
202 are formed with respective chamfered portions 215, 225
chamfered to vertically rise up from the surfaces of the substrates
201a, 202a, and in a fitted state, gaps 200g3 to be cavities for
forming the communication diaphragms 200b3 are formed between the
chamfered portions 215 and between the chamfered portions 225,
respectively. The chamfered portions 215, 225 are not formed at
areas making contact with the outer frame 203 (FIGS. 2 to 5).
[0146] When the first mold 210 and second mold 220 are fitted, the
first protrusion 210 and second protrusion 220 arranged alternately
like a checkerboard are respectively inserted in the inserting
portions 240, 230 of the other molds, and tip surfaces of the first
protrusion 201 and second protrusion 202 respectively abut against
the substrates 202a, 201a of the other molds (FIG. 9, FIG. 11).
[0147] As described above, after the first and second molds 201,
202 are fitted, frame bodies 203a, 203b forming the outer frame 3
are abutted against four peripheral surfaces of the substrates
201a, 202a to form the outer frame 203 of square shape on plan
view.
[0148] Accordingly, when the first and second molds 201, 202 and
the frame bodies 203a, 203b configured as described above are
fitted, gaps 200g, 200g3 are formed along the outer frame 203
between the first protrusions 210 of the first mold 201, and
between the second protrusions 220 of the second mold 202 between
chambered portions 215, 225, and between the first protrusion 210
and second protrusion 220 along the outer frame 203 as shown in
FIGS. 8 and 9.
[0149] For the gap 200g formed along an inner surface of the outer
frame 203, a gap on the larger opening 200e1 side is formed to be
thinner than the smaller opening 200e2, and a minute drawing
gradient, for example, a drawing gradient .alpha.2 on the order of
0.38.degree. is formed on the side surface to improve removability
(FIG. 6, FIG. 8).
[0150] After the molds are fitted, a material made of thermoplastic
elastomer is charged into the gaps 200g, 200g3 to be cavities, and
the cavities are filled therewith (FIG. 8). The elastomer used in
the present invention has been described in detail, but
thermoplastic elastomer is preferable in terms of recyclability and
workability. Specifically, thermoplastic elastomers of styrene
base, polyurethane base, polyolefin base, polyvinyl chloride base,
polyester base, or polyamide base, or the like are used.
[0151] When a predetermined time passes after a finish of filling
the material, the frame bodies of the outer frames 203a, 203b are
removed to separate the first and second molds 201, 202. At this
time, a structure formed in the mold remains in the first mold 1
side having more protrusions (FIG. 9). Toward the base of the
second protrusion 220 of the second mold 202 there is provided with
the drawing gradient on the side to thereby allow the structure to
be easily stripped from a cavity surface, and can be neatly drawn
from the structure.
[0152] After the mold 200a is separated and the second mold 202 is
drawn, a worker removes the cushion 200b remaining in the first
mold 201. At this time, in the cushion 200b remaining in the first
mold 201, the lattice formed by the first protrusion 210 of the
first mold 201 and the base of the second mold 202 forms the larger
opening 200e1, and the lattice formed by the tip thereof forms the
smaller opening 200e2.
[0153] Therefore, when removing the cushion 200b from the first
mold 201, the worker picks an opening edge of the small opening
200e2 and successively strips attached portions between the
surfaces of the first protrusions 210 and the diaphragms 200b1 and
200b2, the communication diaphragms 200b3 and 200b4 of the cushion
200b to remove the cushion 2002b from the mold. This removal
operation can be easily carried out since it can be effected while
picking the opening edge of the small opening 200e2.
[0154] As described above, when the cushion 200b is removed from
the first mold 201, the diaphragms 200b1, 200b2 of the cushion 200b
can be smoothly removed from the mold without attachment or
blocking of the product due to drawing gradients .alpha.1 provided
on the side surfaces of the first and second molds 201, 202.
[0155] Especially, in the cushion 200b, the comers of the opening
200e1 at the bases of the first protrusion 210 and the second
protrusion 220 that are likely to cause attachment are provided
with the chamfered portions 215, 225 to have obtuse angles, so that
separation of the fitted first and second molds 201, 202 or removal
of the cushion 200b remaining in the first mold 201 can be carried
out more smoothly.
[0156] Thus, the mold 200a for a cushion allows the thin and
substantially lattice-like diaphragms 200b1, 200b2 of cushion 200b
formed in the cavity to be neatly and smoothly removed without
attachment or blocking trace.
[0157] As described above, the cushion 200b formed by the mold 200a
has the thin diaphragms 200b1, 200b2, and the side wall 200b4
arranged in a lattice on plan view, and the openings 200e1 and
relatively smaller openings 200e2 are arranged like a checkerboard
(FIG. 4, FIG. 5).
[0158] Also, the communication diaphragms 200b3 of the larger
openings 200e1 formed by the chamfered portions 215, 225 provided
on the first and second protrusions 210, 220 are formed such that
the comers of the adjacent smaller openings 200e2 communicate with
each other through the communication diaphragms 200b3. The
communication diaphragm 200b3 is formed in a vertical isosceles
triangle on side view, and formed like the corner of the larger
opening 200e1 by an upper half and a lower half of the cushion
200b. The communication diaphragm 200b3 changes an angle to
90.degree. at the center of the cushion 200b along the thickness,
that is, at half of the height of the diaphragms 200b1 and 200b2,
and is adapted to cross substantially in an X shape on plan view
(FIG. 4, FIG. 5).
[0159] As described above, providing the communication diaphragm
200b3 causes the corner of the opening 200e1 to have an obtuse
angle, thereby preventing attachment of the product during removal
from the mold.
[0160] In the area where the comers of the openings 200e1 and 200e2
come close to each other, the comers of the opening 200e2 are
adapted to make contact with each other by the communication
diaphragm 200b3.
[0161] The cushion 200b has a lattice formed by combination of
octagons and squares, and when seen from the rear, the octagon on
the surface corresponds to the square on the rear, and the square
on the surface corresponds to the octagon on the rear. Thus,
crossing portions on the surface of the diaphragm are eliminated
unlike the conventional cushion, thereby preventing disadvantage of
increased bounce partially generated in the crossing portion
between the diaphragms of the cushion 200b.
[0162] The inside is also provided with a crossing portion of the
diaphragms, which presents satisfactory pressure distribution.
Thus, the cushion 200b presents satisfactory cushioning.
[0163] The cushion 200b formed substantially in a lattice on plan
view includes horizontal and vertical diaphragms 200b1, 200b2, side
wall 200b4, and communication diaphragm 200b3. The diaphragms
200b1, 200b2, and side wall 200b4 arranged in the lattice are
buckled when the use's weight is applied to function as a
cushion.
[0164] The cushion 200b is used as a cushion for a bed, a chair, a
sofa, or the like, and for a large article such as a bed, the
cushions 200b are vertically and horizontally arranged to be
integrated by adhesion or a stapler to form a bed 200h as shown in
FIG. 10.
[0165] When vertically and horizontally arranging the cushion 200b
to form a bed surface, arranging as pairs the cushions 200b with
the upper and lower surfaces of the adjacent cushions 200b
alternate causes thick portions and thin portions of the peripheral
side wall 200b4 to be alternately arranged, thereby achieving
uniform elasticity on the bed surface without poor thickness
uniformity of the side wall 200b4.
[0166] The elastomer used in the present invention has Shore A
hardness of 10 to 40, preferably 15 to 35. When the elastomer
having the above described hardness is used for diaphragms for a
bed cushion for a structure where thin and vertical diaphragms are
arranged in a lattice, the diaphragms are deformed so as to be
buckled when load is applied. Therefore, the cushion causes no
feeling of touching a bottom and has flexibility, high absorption
of light load. It also has high durability.
[0167] The second embodiment of the present invention of the
application achieves effects as described below.
[0168] The cushion 200b with thin and vertical diaphragms 200b1,
200b2 arranged in the lattice can be formed using the mold for a
cushion 200a by injecting a semirigid material such as the
thermoplastic elastomer into the cavity with the first and second
molds 201, 202 and the outer frame mold 203 being fitted.
[0169] After the cushion 200b is formed, dismantling the outer
frame mold 203 and the first and second molds 201, 202 causes the
cushion to remain fitted in the protrusions (the first protrusions
210 or the second protrusions 220) of one of the first and second
molds 201, 202, and each protrusion of the other mold is
simultaneously drawn. Then, the cushion 200b remaining in one mold
can be easily removed from the mold by picking the edges of the
openings formed by drawing the protrusions of the other mold to
strip and draw the cushion from the cavity surface.
[0170] Specifically, in the mold of the second embodiment, the
opening of the cushion is tapered toward the opening at the base by
the drawing gradient provided on the side, thereby allowing the
cushion as the structure to be smoothly and neatly removed from the
mold without attachment or blocking in removal.
[0171] Especially, in the cushion 200b, the corners of the opening
at the bases of the first protrusion 210 and the second protrusion
220 are formed with the chamfered portions to have obtuse angles,
thereby allowing more smooth removal.
[0172] Moreover, improvement in removability can increase height of
formable cushion, which permits forming a thick cushion, highly
setting a stroke of the cushion, and improving elastic touch.
[0173] A cushion is made of elastomer by the mold with thin
diaphragms arranged in a lattice, so that the diaphragms are
appropriately buckled when load is applied on the cushion, thereby
causing no feeling of touching a bottom, having flexibility, and
especially having satisfactory absorption of light load.
[0174] Therefore, by prevention of touching the bottom or equal
distribution of pressure, the cushion can be used for a chair or a
sofa as well as a normal bed, and is ideal for use in a bed for
preventing bedsore.
[0175] A cushion described can be widely used for a bed, a chair, a
seat of an automobile, or the like, particularly when the elastomer
is a styrene based elastomer which maintains satisfactory
flexibility and improves durability.
[0176] A cushion described in claim 4 has especially excellent
flexibility like a water bed, when the cushion is formed using gel
made by adding a softener to the elastomer as a cushion formed by
the mold for a cushion. Further, the cushion has satisfactory
absorption of light load, and is therefore suitable for use, for
example, in a bed for preventing bedsore.
[0177] Next, an embodiment of a third invention of the present
application will be described.
[0178] A cushion 300B shown in FIG. 11 and FIG. 12 is integrally
formed using elastomer, and thin and horizontal diaphragm 300b2 and
side wall 300b1 are arranged in a lattice on plan view, and
peripheries thereof are integrally formed to be surrounded by a
diaphragm 303b3.
[0179] Air vents 300c are respectively drilled in the vertical and
horizontal diaphragm 300b1, 300b2 and peripheral side wall 300b3,
and spaces in the respective lattices surrounded by the vertical
diaphragm 300b1, horizontal diaphragm 300b2, and side wall 300b3
communicate. This permits air to freely pass through the air vents
200c.
[0180] The cushion 300B is assembled as shown in FIG. 16 and
integrally formed using a mold 300d that can be dismantled.
[0181] As described above, the cushion 300B made of the
thermoplastic elastomer formed as described above is used as a
cushion for a bed, chair, sofa, or the like with a cover 300D (FIG.
13), and for a large article such as a bed, as described later, the
cushions 300B are vertically and horizontally arranged to be
integrated by adhesion or a stapler for use as a bed cushion (FIG.
19, FIG. 20).
[0182] The cushion 300B formed substantially in a lattice on plan
view includes vertical and horizontal diaphragms 300b1, 300b2, and
side wall 300b3. The diaphragms 300b1, 300b2, 300b3 arranged in the
lattice are buckled when the user's weight is applied to function
as a cushion with high elasticity.
[0183] Specifically, the vertical and horizontal diaphragms 300b1,
300b2, and side wall 300b3 are formed to have tapered sections so
as to be thinner at upper edges than lower edges (FIG. 12), so that
bending of the vertical diaphragm 300b1, horizontal 300b2, and side
wall 300b3 to be contact surfaces of the cushion 300B is gradually
reduced from a lower edge to the upper edge, and flexible
deformability can be achieved at the upper edge.
[0184] The vertical and horizontal diaphragms 300b1, 300b2 and side
wall 300b3 are elastically deformed satisfactorily in an improved
way by providing the air vent 300c in its predetermined position.
The air vent 300c is essentially a hole for ventilation for the
space inside the lattice, but also concerns an elastic deformation
property of the vertical and horizontal diaphragms 300b1, 300b2,
and side wall 300b3.
[0185] Injection noise of air occurs partly resulting from the
vertical and horizontal diaphragms 300b1, 300b2, and side wall
300b3 being drastically bent. As described above, however, the air
vents 300c are provided in the vertical and horizontal diaphragm
300b1, 300b2, and wide wall 300b3 to thereby soften the areas. That
is, when the user's weight is applied, the air vent 300c is
deformed to be enlarged or to be an ellipse, for example, thereby
relieving drastic bending caused by the load.
[0186] A condition for obtaining satisfactory elastic deformation
is that the air vent 300c is provided in each of the vertical and
horizontal diaphragms 300b1, 300b2, and side wall 300b3 at a
position ranging from 60% to 80% of the height h, and in this
embodiment, one air vent 300c is provided at the position of 70% of
the height h for each diaphragm (FIG. 17, FIG. 18).
[0187] A diameter of the air vent 300c is an important factor of
satisfactory elastic deformation as well as a location. The size of
the air vent is set within a range of 3 to 10 cm square to thereby
maintain a sufficient venting function and provide the vertical and
horizontal diaphragms 300b1, 300b2, side wall 300b3 with a
satisfactory elastic deformation property. The air vent can be
formed into any shape, but a circular shape is preferable for
natural elastic deformation of the diaphragms and side wall.
[0188] Thus, for the cushion 300B including the vertical and
horizontal diaphragms 300b1, 300b2, and side wall 300b3, the upper
edges that are the softest are elastically bent and deformed to
achieve soft feeling of touch in an initial state where the user
300A touches the contact surface, the diaphragms 300b1, 300b2, and
side wall 300b3 start to be bent from the areas of the air vents
300c as the user's weight is applied, and a central portion is
buckled to be appropriately elastically deformed. This allows the
cushion 300B to achieve soft cushioning like a tip of a brush
without feeling of touching a bottom or partial protrusions (FIG.
13).
[0189] Also, as described above, each diaphragm is provided with
the air vent 300c, so that even if the user's weight is applied on
the cushion 300B, and the diaphragms 300b1, 300b2, and the side
wall 300b3 are buckled with an opening 300b4 of the lattice blocked
by a body surface of the user 300A, air in a space in the lattice
flows out into an adjacent lattice through the air vent 300c. As a
result, the disadvantage of the injection noise generated by air in
the space in the lattice drastically flowing from a gap between the
body surface of the user and the opening 300b4 can be prevented
even when the inside of the diaphragm of the contact area is
compressed by the weight or change of attitude of the user.
[0190] For the air vents c provided in the diaphragms 300b1, 300b2,
and side wall 300b3 as described above, two air vents may be
provided in each of the diaphragms 300b1, 300b2, side wall 300b3 at
a height ranging from 60% to 80% of the height h like a cushion
300B' shown in FIG. 17. In this case, the elastic deformation
property of the diaphragm can be set finely by changing an opening
area of a pair of air vents 300c or location within the above
described range. More than two air vents may be provided as the air
vents 300C.
[0191] Next, a bed cushion 300B2 shown in FIG. 14 and FIG. 15 will
be described.
[0192] This bed cushion 300B2 includes a cushion body 300B2' and a
frame body 300E, and is used as a cushion for a normal bed or a bed
for preventing bedsore.
[0193] The cushion body 300B2' is configured as one piece of
cushion having substantially identical size to a bottom surface of
a bed by vertically and horizontally arrange the cushions 300B in
one plane and attaching peripheral diaphragms 300b3 of adjacent
cushions using a stapler or an adhesive (FIG. 19). The frame body
300E formed by a wooden frame or the like is provided around the
cushion body 300B2' configured as described above to hold a
periphery of the cushion body 300B2'.
[0194] The diaphragms 300b1, 300b2, and side wall 300b3
constituting the cushion 300B of this embodiment are set to have a
height of 10 to 300 mm and a lattice width of diaphragm of 5 to 200
mm. For the diaphragms 300b1, 300b2, and side wall 300b3 of the
cushion 300B used as the normal bed or the bed for preventing
bedsore, a ratio of the diaphragm 300b1 arranged vertically of the
bed and the diaphragm 300b2 arranged horizontally of the bed may be
identical to a vertical-to-horizontal ratio of the bed.
[0195] A described above, the configured cushion body 300B2' is
fitted in the frame body 300E formed by wooden plates or the like,
the peripheral diaphragm 300b3 of the cushion body 300B2' is
mounted to be fixed to an inner peripheral surface of the frame
body 300E by attaching means such as adhesion or a stapler, thereby
holding the periphery of the cushion body 300B2' by the frame body
300E.
[0196] The cushion 300B2 can be placed on the bottom surface of the
bed to be used. The cushion 300B2 is preferably used with a cloth
cover or the like.
[0197] The cushion 300B2 configured as described above provides a
soft touch like a water bed by the elasticity property of each
cushion 300B. The user's weight can be received with the periphery
of the cushion body 300B2' suspended by the frame body E, thereby
preventing disadvantage that the peripheral area is crashed to
touch the bottom even when load is applied near the periphery of
the cushion body 300B2' by, for example, rolling over of the
user.
[0198] In the cushion 300B2, the air vent 300c is provided in the
side wall 300b3 of each cushion 300B corresponding to the
peripheral surface of the cushion body 300B2', but the side wall
does not always require the air vent 300c. Even if the side wall
300b3 is not provided with the air vent 300c, air can be flown out
through the air vent 300 of the adjacent diaphragms 300b1, 300b2,
and can be flown out through the opening 300b4 of the lattice near
the peripheral surface of the cushion body 300B2', thereby allowing
an effect of preventing air injection noise to be maintained.
[0199] In this embodiment, between the adjacent cushions 300B, the
air vents 300c respectively provided in the diaphragms 300b3 are
aligned to cause the space of insides of the lattices of the
cushions 300B to communicate. This structure is effective in
preventing injection noise. However, the air vent 300c of the side
wall 300b3 is not necessarily required, and air can be flown out
through the diaphragms 300b1, 300b2 other than the side wall 300b3
or the openings 300b4 without the air vent 300c provided, thereby
allowing an effect of preventing air injection noise to be
maintained.
[0200] The cushion body 300B2' can be used as a floor cushion to be
laid on a mat or the like as it is without the frame body 300E
mounted. Also in this case, the cushion body 300B2' covered with a
sheet such as a cloth is preferably used.
[0201] As described above, the third embodiment of the invention of
the present application is the cushion made of elastomer and
integrally formed with the elastic thin diaphragms 300b, 300b2, and
the side wall 300b3 arranged in a lattice on plan view, wherein the
air vent 300c is provided in an appropriate position of each of the
diaphragms 300b1, 300b2, and the side wall 300b3, so that even if
the diaphragms are buckled with the opening 300b4 of the lattice
blocked by the body surface of the user 300A, the air in the space
in the lattice flows out into the adjacent lattice through the air
vent 300c. Therefore, even if the air in the lattice of the
diaphragm is compressed by rolling over of the user 300A as is
conventional, injection of compressed air from the opening is
avoided, and thus, generating the injection noise of the air in
rolling over can be effectively prevented.
[0202] Further, providing the air vent in the appropriate position
of each of the diaphragms 300b1, 300b2, and the side wall 300b3 as
described above achieves a flexible deformation property of the
diaphragms 300b1, 300b2, and the side wall 300b3 and softens the
touch, so that a feeling of use with a cushioning property closer
to a water bed can be obtained.
[0203] The cushion 300B includes the diaphragms 300b1, 300b2, and
the side wall 300b3 having tapered sections from lower edges to
upper edges, thereby providing flexible deformation like a tip of a
brush at the upper edge of each of the longitudinal diaphragm
300b1, the horizontal diaphragm 300b2, and the side wall 300b3 to
be a contact surface of the cushion 300b. Then, in an initial
contact state where the weight of the user 300A is applied, as
described above, the upper edge is flexibly and elastically
deformed further forward than the buckled side wall, and very soft
feeling of touch that has never been obtained before can be
achieved together with flexibility of the diaphragm by the air vent
300c as described above.
[0204] Next, a fourth embodiment of the invention of the present
application will be described with reference to the drawings.
[0205] FIG. 16 and FIG. 17 show a mold 400a for a cushion that
embodies the present invention. The mold 400a includes a first mold
401 to be a lower mold, a second mold 402 to be an upper mold, and
an outer frame 403 to be fitted to surround four peripheral
surfaces of the fitted first and second molds 401, 402.
[0206] The cushion 400b formed by the mold 400a is integrally
formed using elastomer, thin and vertical diaphragms 400b2 and
horizontal diaphragms 400b1 are arranged in a lattice on plan view,
and peripheries thereof are surrounded by a diaphragm 400b3.
[0207] The first mold 401 has a predetermined number of middle
protrusions 401b integrally formed vertically and horizontally in a
protruding manner on an upper surface of a substrate 401a of
rectangular shape on plan view through spaces to be inserting
portions 401c. The middle protrusions 401b and inserting portions
401c are alternately arranged like a checkerboard on plan view
(FIG. 16).
[0208] The second mold 402 has a predetermined number of
protrusions 402b integrally formed vertically and horizontally on a
lower surface of a substrate 402a through insertion spaces 402c. A
space keeping protrusion 402d that relatively slightly protrudes
from the lower surface of the substrate 402a in each insertion
space 402c is integrally formed in a protruding manner.
[0209] The space keeping protrusions 402d and protrusions 402b
formed in the insertion spaces 402c are alternately arranged like a
checkerboard on plan view, and are adapted to be inserted in the
respective inserting portions 401c of the first mold 401 when the
molds are fitted. The middle protrusions 401b of the first mold 401
are adapted to be inserted in the respective insertion spaces 402c
of the second mold 402, their tip surfaces abutting against end
surfaces 402d' of the space keeping protrusions 402d with shapes
thereof matched.
[0210] Specifically, each middle protrusion 401b of the first mold
401 has a section shape identical to that of each space keeping
protrusion of the second mold 402, and is adapted to have the same
height and contour as the protrusion 402b of the second mold 402 in
an abutting state when the molds are fitted. Each protrusion 402b
of the second mold 402 is fitted in the inserting portion 401c of
the first mold 401 to abut against the upper surface of the
substrate 401a when the molds are fitted. With both the first and
second molds 401, 402 fitted, frame bodies 403a, 403b forming an
outer frame 403 are abutted against four peripheral surfaces of the
substrates 401a, 402a to form an outer frame 403 of square shape on
plan view (FIG. 17).
[0211] Accordingly, when both the first and second molds 401, 402,
and frame bodies 403a, 403b configured as described above are
fitted, as shown in FIG. 17, a gap for forming a lattice-like
cushion 400b to be a structure, that is, a cavity 404 is formed
between each coupled article of the middle protrusion 401b of the
first mold 401 and the space keeping protrusion 402d of the second
mold 402 and each protrusion 402b of the second mold 402 (FIG. 18).
As described above, after the molds are fitted, a material made of
thermoplastic elastomer is charged into the cavity 404, which is
filled therewith.
[0212] Each protrusion 402b of the second mold 402 is provided with
a slight drawing gradient toward a protruded end so as to
facilitate stripping the product formed in the cavity 403 from a
surface of the cavity. Therefore, a drawing gradient of the
protrusion 402b is set in such a manner that the cushion 400b
formed remains in the first mold 401 that has relatively higher
adhesion in separation of the first mold 401 and second mold 402,
and the frame bodies 403a, 403b (FIG. 19).
[0213] After separation of the mold 400a, a worker removes the
cushion 400b remaining in the first mold 401. At this time, the
cushion 400b remaining in the first mold 401 is formed with an
opening 400b4' that is formed after drawing of the space keeping
protrusion 402d together with a hollow portion 400b4 of a lattice
formed by the protrusion 402b of the second mold 402.
[0214] When removing the cushion 400b, the worker can pick an
opening edge of the opening 400b4' and successively strip attached
portions between the surface of the middle protrusion 401b 1 and
the diaphragms 400b1, 400b2, and side wall 400b3 to remove the
cushion 400b from the mold, which permits smooth removal operation
of the structure.
[0215] In the cushion 400b removed from the mold, a partition line
400b5 remains on a peripheral wall in the opening 400b4' formed by
the coupled article of the space keeping protrusion 402d and the
middle protrusion 401b. An inner surface of the opening 400b4'
formed at the protrusion 402b of the second mold 4002 is somewhat
tapered (FIG. 20). The mold 400d of the present invention may be
set in such a manner that the structure remains in the second mold
402 side when the cushion 400b is formed as described above. A
ratio of a height between the space keeping protrusion 402d of the
second mold 2 and the middle protrusion 401b of the first mold 401,
that is, a position of the partition line 400b5 may be
appropriately changed.
[0216] The drawing gradient may be provided on the coupled article
of the space keeping protrusion 402d and the middle protrusion 401b
in accordance with the forms of the lattice diaphragms 400b1, 400b2
of the structure.
[0217] Each protrusion 402b of the second mold 402 is provided with
a slight drawing gradient toward a protruded end so as to
facilitate stripping the structure formed in the cavity 404 from a
surface of the cavity. Therefore, a drawing gradient of the
protrusion 402b is set in such a manner that the cushion 400b
formed in the cavity 404 remains in the first and second molds 401,
402 that has relatively higher adhesion by separation of the first
and second molds 401, 402, and the frame bodies 403a, 403b (FIG.
19).
[0218] When removing the cushion 400b, the worker can pick an
opening edge of the opening 400b4' and successively strip attached
portions between the surface of the middle protrusion 400b1 and the
diaphragms 400b1, 400b2, and side wall 400b3 to remove the cushion
400b from the mold, which permits smooth removal operation of the
structure.
[0219] The cushion 400b formed substantially in a lattice on plan
view includes vertical and horizontal diaphragms 400b1, 400b2, and
peripheral side wall 400b3. The vertical and horizontal diaphragms
400b1, 400b2, and peripheral side wall 400b3 arranged in the
lattice are buckled when the user's weight is applied to function
as a cushion.
[0220] The diaphragms in a lattice are set to have a height of 10
to 300 mm and a lattice width of 5 to 200 mm.
[0221] For the diaphragms of the cushion 400b used as the normal
bed or the bed for preventing bedsore, a ratio of the diaphragms
400b1 arranged vertically of the bed and the diaphragms 400b2
arranged horizontally of the bed may be identical to a length to
width ratio of the bed 400c.
[0222] As described above, the cushion 400b is used as a cushion
for a bed, a chair, a sofa, or the like, and for a large article
such as a bed, as shown in FIG. 21, the cushions 400b are
vertically and horizontally arranged to be integrated by adhesion
or a stapler to form a bed 400c.
[0223] The fourth embodiment having the above described features
produces below mentioned effects.
[0224] The mold for the cushion of the invention is configured as
described above, so that the thermoplastic elastomer is injected
into the cavity 404 with the first and second molds 401, 402 and
the outer frame mold 403 fitted to form the cushion with thin and
vertical diaphragms 400b1, 400b2, and the side wall 400b3 arranged
in a lattice. Then, in dismantling the first and second molds 401,
402 and the outer frame mold 403, the cushion 400b as the structure
remains fitted in each middle protrusion 401b of the first mold 401
having relatively high adhesion.
[0225] As described above, for the cushion 400b remaining in the
first mold 401, with the second mold 403 removed, each protrusion
402b of the second mold 402 is drawn from the structure, and a
portion of the space keeping protrusion having abutted against the
end surface of the middle protrusion 401b of the first mold 401 is
removed to be opened.
[0226] Therefore, when taking out the structure from the first mold
401, the worker can pick the edges of the opened structure to strip
and draw the cushion 400b as the structure from the cavity 404,
allowing easy and neat stripping without blocking traces.
[0227] In the cushion 400B with thin diaphragms 401, 402 and the
outer frame mold 403 arranged in a lattice, the diaphragms 401, 402
and the outer frame mold 403 are buckled in particular at the
partition lines when load of the user is applied on the cushion,
thereby causing no feeling of touching a bottom, and having
flexibility and satisfactory absorption of light load. Therefore,
by prevention of touching the bottom or equal distribution of
pressure, the cushion can be used for a chair or a sofa as well as
a normal bed, and is especially ideal for use in a bed for
preventing bedsore.
[0228] Next, a fifth embodiment of the invention of the present
application will be described.
[0229] A cushion 500B shown in FIG. 22 and FIG. 34 is integrally
formed using elastomer, thin vertical horizontal diaphragms 500b2
and longitudinal diaphragms is 500b1 are arranged in a lattice on
plan view, and peripheries thereof are surrounded by a side wall
500b3.
[0230] The cushion 500B is integrally formed using the same mold as
in the fourth embodiment.
[0231] The cushion 500B formed substantially in a lattice on plan
view includes the longitudinal diaphragm 500b1, the horizontal
diaphragm 500b2, and the side wall 500b3. The diaphragms 500b1,
500b2, and the side wall 500b3 arranged in a lattice are buckled
when the user's weight is applied to function as a cushion with
high elasticity.
[0232] Specifically, the longitudinal diaphragm 500b1, the
horizontal diaphragm 500b2, and the side wall 500b3 are formed to
have tapered sections so as to be thinner at upper edges than lower
edges thereof, so that bending of the longitudinal diaphragm 500b1,
the horizontal diaphragm 500b2, and the side wall 500b3 to be a
contact surface of the cushion 500B is gradually reduced from the
lower edge to the upper edge, and satisfactory deformability can be
achieved at the upper edge.
[0233] Thus, for the cushion 500B including the longitudinal
diaphragm 500b1, the horizontal diaphragm 500b2, and the side wall
500b3, the upper edges that are the softest are elastically bent
and deformed to achieve soft feeling of touch in an initial state
where the user touches the contact surface, and further, a rear of
a central portion of each of the longitudinal diaphragm 500b1, the
horizontal diaphragm 500b2, and the side wall 500b3 is buckled to
be appropriately elastically deformed as the user's weight is
applied, thereby allowing satisfactory cushioning without feeling
of touching a bottom or partial protrusions.
[0234] Next, a cushion 500B2 shown in FIG. 23 will be
described.
[0235] The elastic thin cushion 500B2 is a cushion made of
elastomer and integrally formed with elastic thin longitudinal
diaphragms 500b1, horizontal diaphragms 500b2, and side walls 500b3
arranged in a lattice on plan view similarly to the cushion 500B,
but each of the longitudinal diaphragm 500b I, the horizontal
diaphragm 500b2, and the side wall 500b3 is tapered only at an
upper edge 500B10. Each of them becomes gradually thinner and is
tapered toward the upper edge.
[0236] Specifically, in the cushion 500B2, the longitudinal
diaphragm 500b I, the horizontal diaphragm 500b2, and the side wall
500b3 become gradually thinner and are tapered toward the upper
edges only near the upper edges 500B10.
[0237] Therefore, in an initial state where a user touches the
contact surface, the longitudinal diaphragm 500b I, the horizontal
diaphragm 500b2, and the side wall 500b3 are partly and flexibly
buckled and deformed at the upper edges 500B 0 with taper to
achieve a softer feeling of touch (FIG. 24). Then, as the user's
load increases, a central portion of each of the longitudinal
diaphragm 500b1, the horizontal diaphragm 500b2, and the side wall
500b3 is bent to have a triangular or S shaped section to be
appropriately elastically deformed (shown by phantom lines),
thereby achieving satisfactory cushioning without a feeling of
touching the bottom or a protrusion caused by a crossing portion of
the diaphragm. The feeling of touch and cushioning are similar to
those of a water bed, and are very soft. A ratio of tapered
thickness of the tapered upper edges of the vertical diaphragm and
the horizontal diaphragm as described above may be appropriately
changed in accordance with elasticity or thickness of the
elastomer.
[0238] Next, a cushion 500B3 shown in FIG. 25 will be
described.
[0239] The cushion 500B3 is a cushion made of elastomer and
integrally formed with elastic thin longitudinal diaphragms 500b1,
horizontal diaphragms 500b2, and side walls 500b3 arranged in a
lattice on plan view similarly to the cushion 500B2, but each of
the diaphragms 500b1, 500b2, and the side wall 500b3 has an upper
edge 500b1 I that becomes gradually thinner by forming a plurality
of steps 510 near the upper edges 500b11. For the steps formed on
the tapered portions, two steps 510 are formed to have three levels
of tapered thickness in this embodiment, but two levels or four or
more levels are acceptable.
[0240] When the longitudinal diaphragm 500b I, the horizontal
diaphragm 500b2, and the side diaphragm 500b3 become gradually
thinner by forming the plurality of steps 510 as described above, a
height of the upper edge may be increased or decreased. For
example, the diaphragms and the side wall may be provided with
appropriate number of steps 510 across the diaphragms and the side
wall from the lower edge to the upper edge, and gradually tapered
along the entire height of the diaphragms and the side wall like
the taper of the cushion 500B.
[0241] In the cushion B3, taper is provided by forming the steps
510 along the upper proximity of the diaphragms 500b1, 500b2, and
side wall 500b3 similarly to the cushion B2, and therefore the
cushion B3 has a satisfactory cushioning property similarly to the
cushion 500B2. The steps 510 are formed, which allows portions bent
by the load and a bending manner (buckling manner) to be relatively
easily set, thereby providing uniform elastic bounce by the
diaphragms 500b1, 500b2 and side wall 500b3 and equal cushioning on
the contact surface of each area.
[0242] Next, a bed cushion 500B40 shown in FIG. 26 will be
described.
[0243] This cushion 500B40 is used as a cushion for a normal bed or
a bed for preventing bedsore, and includes a cushion body 500B41
formed by vertically and horizontally arranging the cushion 500B
configured similarly to the cushion body 500B (or 500B2, 500B3),
and a frame body 500B42 holding the cushion body 500B41.
[0244] The cushion body 500B41 is configured as one piece of
cushion having substantially identical size to a bottom surface by
vertically and horizontally arranging the cushions 500B or 500b2,
500b3 in one plane and attaching peripheral diaphragms 500b3 of
adjacent cushions using a stapler or an adhesive.
[0245] The cushion 500B41 configured as described above is fitted
in the frame body 500B42 formed by wooden plates or the like, the
peripheral diaphragm 500b3 in contact with the periphery of the
cushion body 500B41 is mounted to be fixed to an inner peripheral
surface of the frame body 500B42 by attaching means such as
adhesion or a stapler 545, thereby holding the entire periphery of
the cushion body 500B41 by the frame body 500B42.
[0246] The bed cushion 500B40 configured as described above is
preferably covered with a cloth cover 544. The bed cushion 500B40
can be placed on a bottom surface of the bed to be used.
[0247] Specifically, the cushion 500B40 provides satisfactory
cushioning and a soft touch like a water bed similarly to the
cushions 500B, 500B2, 500B 3. The user's weight can be received
with the periphery of the cushion body 500B41 suspended by the
frame body 500B42, thereby preventing disadvantage that the
peripheral area is crashed to touch the bottom even when load is
applied near the periphery of the cushion body 500B41 by, for
example, rolling over of the user.
[0248] The diaphragms 500b1, 500b2, and side wall 500b3
constituting the cushion 500B40 of this embodiment are set to have
a height of 10 to 300 mm and a lattice width of 5 to 200 mm. For
the diaphragms 500b1, 500b2, and side wall 500b3 of the cushion
body 500B, 500B2, 500B3 used as the normal bed or the bed for
preventing bedsore, a ratio of the vertical diaphragm 500b1
arranged vertically of the bed and the horizontal diaphragm 500b2
arranged horizontally of the bed may be identical to a vertical to
horizonatl ratio of the bed.
[0249] The cushion formed substantially in a lattice on plan view
includes the vertical diaphragm, the horizontal diaphragm, and the
peripheral side walls. The diaphragms and the side wall arranged in
the lattice are buckled when the user's weight is applied to
function as a cushion with high elasticity.
[0250] Specifically, the diaphragms and the side wall are formed to
have the tapered sections so as to be thinner at the upper edges
than the lower edges thereof or to become gradually thinner toward
the upper edge, so that bending of the diaphragms and the side wall
to be a contact surface of the cushion is gradually reduced from
the lower edge to the upper edge, and satisfactory deformability
can be obtained at the upper edge.
[0251] For the cushion B including the diaphragms 500b1, 500b2,
500b3, the upper edges that are the softest are elastically bent
and deformed to achieve soft feeling of touch in an initial state
where the user touches the contact surface.
* * * * *