JP7486391B2 - mattress - Google Patents

Description

The present invention relates to a mattress that distributes body pressure according to each part of the user's body, and a method for manufacturing a cushion body for use in mattresses and other products.

Conventionally, mattresses have been proposed that support a user while appropriately distributing the body pressure of each part of the user's body. For example, according to the mattress of Patent Document 1, a plurality of grooves extending in the width direction are arranged along the length on the surface of a base body made of a resin foam of uniform thickness in the length and width directions. By changing and setting the depth and arrangement pitch of the plurality of grooves, a plurality of zones with different hardness corresponding to each part of the user's body are formed along the length. In particular, the groove arrangement pitch is set narrower in the zones corresponding to the user's shoulders and pelvis, making the zones more flexible than the other zones.

The bedding mattress in Patent Document 2 is a one-piece bedding mat formed by profiling soft urethane foam of the same material. This is achieved by forming a three-dimensional curved uneven surface with a different outer shape on the surface of the mat for three areas corresponding to the head, waist, and legs, which are divided in the longitudinal direction of the mat, to give each of the three areas different hardness. Preferably, the hardness ratio for the three areas corresponding to the head, waist, and legs is within the range of 1.0-2.0:1.1-3.0:1.0.

These create zones that correspond to the human head, lower back and legs, providing appropriate support according to the body pressure of each area, while also providing excellent breathability and a comfortable sleep.

JP 2007-61295 A Japanese Patent Application Laid-Open No. 10-272036

However, in the conventional example shown in Patent Document 1, although the hardness is varied by changing the settings of the depth and arrangement pitch of the grooves, there was an issue that it was difficult to achieve fine differences in hardness. As only a number of grooves are formed on the surface of the base, the surface between the grooves is flat, and there was an issue that force was required when the user turned over in bed.

In addition, in the conventional example shown in Patent Document 2, the uneven surface of a three-dimensional curved surface is formed on the matte surface, so the uneven surface shape is limited, and there is a limit to the types of shapes that can be formed.

The object of the present invention is to solve the problems of the past and to provide a mattress and a method for manufacturing a cushion body in which the hardness is appropriately set according to each part of the user's body.

The mattress according to the first aspect of the present invention is a substantially rectangular parallelepiped mattress (1) made of a resin foam, having a predetermined thickness in the thickness direction, and having a surface extending in the longitudinal and width directions. On one surface, convex portions (2) and concave portions (3) are alternately arranged in a direction along the longitudinal direction to form a plurality of rows (R), and the convex portions and concave portions are alternately arranged in a direction along the width direction to form a plurality of rows (L). In the thickness direction, one surface side is the upper side and the opposite side is the lower side, and a support layer (6) is formed below the convex portions and the concave portions. The convex portions have an apex (8) that protrudes upward in the thickness direction, and are formed at an angle from a bottom portion (4) adjacent to the convex portion, which is the most recessed portion of the concave portion, toward the apex. The convex portions include those having two or more apexes, and the types of the convex portions are classified according to the number of apexes, and there are multiple types of the convex portions.

According to this, the mattress has rows and columns of alternating convex and concave portions, and the convex portions are of multiple types, each with two or more peaks. That is, the convex portions formed in the longitudinal and transverse directions include those with two or more peaks, and are composed of convex portions with different numbers of peaks, so that a wide variety of surface shapes can be formed and the hardness can be adjusted. Therefore, the mattress can flexibly set the hardness according to the difference in the body pressure of the user's body parts. Also, on one surface, the rows are formed by alternating convex portions and concave portions having two or more peaks in the longitudinal direction. When the user turns over in his/her sleep, the concave portions induce the rotation of the axis of the body that accompanies the turning, and the slope of the convex portions generates a repulsive force in a direction intersecting the slope while being compressed, thereby supporting the body. Therefore, the rotational force of the axis of the body can be assisted.

In addition, in the mattress, in the convex portion including multiple types with different numbers of the peaks, the length of the base (10) facing the peaks in the convex portion may be shorter for the convex portion with fewer peaks. In this case, the difference in the base length corresponding to the type of convex portion can provide different hardness and hardness characteristics.

The mattress may also be arranged such that, on at least one surface, the convex portions and the concave portions are offset from each other in the longitudinal direction and the width direction in a staggered arrangement.

In this case, the surface of the mattress has a staggered arrangement of convex and concave portions that are offset in the longitudinal and lateral directions, so that each zone has a substantially uniform hardness. Also, the rows are formed by alternating convex and concave portions in the longitudinal direction, and the rows are formed by alternating convex and concave portions in the lateral direction. When the user turns over in their sleep, the concave portions induce the axis of the body to turn over as the user turns over, and while the slopes of the convex portions adjacent to the concave portions in the lateral direction are compressed, a repulsive force is generated in the direction intersecting the slope to support the body. This can assist the rotational force of the axis of the body, allowing the user to turn over easily.

The mattress may also have a shape in which the convex portion is adjacent to the concave portion in the width direction, and the convex portion and the concave portion are symmetrical with respect to a first imaginary line (13a) that is parallel to the longitudinal direction and passes through the center between the tip of the top portion and the bottom portion.

In this case, the convex and concave portions are formed symmetrically with respect to the first imaginary line in the longitudinal direction, so body pressure can be distributed and supported. Also, because the convex and concave portions are symmetrical with respect to the first imaginary line, two mattresses of the same shape can be formed from a single sheet material using a specific processing method. This makes it possible to improve production efficiency and reduce material costs while maintaining body pressure distribution.

The mattress may be divided into a plurality of zones (Z) in the longitudinal direction, and the types of the convex portions in adjacent zones in the longitudinal direction may be different from each other. In this case, the mattress is configured with a combination of different types of convex portions in adjacent zones, so that a wide variety of surface shapes can be formed, and the hardness of each zone can be adjusted. Therefore, the hardness of the mattress can be flexibly adjusted for each zone according to differences in body pressure of the user's body parts.

The mattress may also include at least two of the three types of convex portions in each of the zones: a first convex portion (2a) having one apex, a second convex portion (2b) having two apexes, and a third convex portion (2c) having three apexes. In this case, the convex portions include two types of convex portions having one to three apexes, so that the user's body pressure can be supported according to the hardness characteristics of each zone.

The mattress may further have a row including the first convex portion formed at any of the boundaries with each of the zones. In this case, the boundary with the zone where the row including the first convex portion is formed can buffer abrupt changes in hardness and distribute body pressure.

The mattress may also have a height pattern (H) in which the convex portion and a specific convex portion (2d) whose top is lower than the convex portion are adjacent to each other across the concave portion in at least some of the rows, and the convex portion and the specific convex portion alternate in height.

In this case, in at least some rows, the convex portions and the specific convex portions are adjacent to each other to form a height pattern, making it easier to turn over in your sleep. When the user turns over in their sleep, the axis of the body is induced to rotate with the turning over by the specific convex portions in addition to the concave portions. Furthermore, while the slopes of the convex portions adjacent to the specific convex portions across the concave portions in the width direction are compressed, a repulsive force is generated in a direction perpendicular to the slope to support the body. This can assist the rotational force of the axis of the body, allowing the user to turn over more easily.

In addition, when the type of the protrusions of the mattress includes the third protrusions, the protrusions and a specific protrusion (2d) whose top is lower than the protrusions may be adjacent to each other across the recess in any of the third protrusions formed in the longitudinal direction, forming a height pattern in which the protrusions and the specific protrusions alternate in height. In this case, the third protrusions form a height pattern (H) that strongly repels body pressure from the width direction, making it easier for the user to turn over in bed.

A method for manufacturing a cushion body according to a second aspect of the present invention is a method for manufacturing a cushion body having a predetermined thickness in the thickness direction, with convex portions and concave portions arranged alternately on one surface, the convex portions having an apex protruding upward in the thickness direction, and formed at an angle from a bottom portion adjacent to the convex portion which is the most recessed portion of the concave portion toward the apex, the convex portions include those having two or more apexes, the types of the convex portions are classified according to the number of apexes, and the method for manufacturing a cushion body having a plurality of types of the convex portions uses a roller (22) that overlaps a plurality of discs (21) in the axial direction and is rotatable about an axis (C) and a cutting means (24) that cuts a sheet material that is the material of the cushion body, the discs having a plurality of cuts on the outer circumferential surface The roller convex portions (26) and roller concave portions (27) are alternately arranged along the circumferential direction, and the rollers form a roller pair (23) in which the roller convex portions and the roller concave portions are arranged in parallel so that they correspond to each other. The rollers use multiple types of rollers corresponding to the types of convex portions in the cushion body by stacking multiple disks in the axial direction. The sheet material is inserted between the roller pair and fed in one direction while being compressed between the roller convex portions and the roller concave portions. Between the roller pair on the feed side of the sheet material, the sheet material before elastic recovery is cut and separated by the cutting means, and the convex portions including types with different numbers of peaks and the concave portions are formed on the cut surface side of the sheet material.

By doing this, when the sheet material is inserted between the pair of rollers in the width direction, rows of convex portions and concave portions are formed in sequence in the portions corresponding to the rollers. Two symmetrical cushion bodies are simultaneously formed across the cutting means in the thickness direction of the sheet material. This makes it possible to manufacture cushion bodies that form convex portions, including types with different numbers of apexes, and concave portions on the cut surface side of the sheet material. In addition, the amount of sheet material that is discarded is minimized.

FIG. 1 is a perspective view showing a mattress 1a of a first embodiment. 1 is a plan view of a mattress 1a of a first embodiment viewed from above in the thickness direction. 1A and 1B are oblique views showing the convex portion 2 and the concave portion 3 of mattress 1a (including 1b), where (a) shows the first convex portion 2a and the first concave portion 3a, (b) shows the second convex portion 2b and the second concave portion 3b, and (c) shows the third convex portion 2c and the third concave portion 3c. 2 (including FIG. 9 ), where (a) is an enlarged view of A1, (b) is an enlarged view of A2, and (c) is an enlarged view of A3. In Figure 4, these are cross-sectional views of the convex portion 2 and the concave portion 3 cut in the direction of row R, where (a) is a cross-sectional view showing the section S2-S2, (b) is a cross-sectional view showing the section S3-S3, and (c) is a cross-sectional view showing the section S4-S4. In Figure 4, these are cross-sectional views of the convex portion 2 and the concave portion 3 cut in the direction of row L, where (a) is a cross-sectional view showing the section S5-S5, (b) is a cross-sectional view showing the section S6-S6, and (c) is a cross-sectional view showing the section S7-S7. 3 is a cross-sectional view showing the cross section S1-S1 in FIG. 2. FIG. 11 is a perspective view showing a mattress 1b of a second embodiment. A plan view of the mattress 1b of the second embodiment seen from above in the thickness direction. 10 is a cross-sectional view showing the cross section S8-S8 in FIG. 9. In Figure 9, it is a partial cross-sectional view showing a cross section S9-S9 of the third convex portion 2c and the third concave portion 3c corresponding to the height pattern H cut along row L, where (a) shows the configuration of the convex portion 2 having the height pattern H, (b) shows the state when the user turns over to one side, and (c) shows the state when the user turns over to the other side. FIG. 2 is a cross-sectional view showing a cushion body manufacturing apparatus 20, taken in a direction intersecting the axial direction.

The mattress 1 embodying the present invention and the method for manufacturing the cushion body will be described below with reference to the drawings. The drawings are used to explain the technical features that can be adopted by the present invention. The configuration of the device shown in the drawings is not intended to be limiting, but is merely an illustrative example.

<Common structure for 1 mattress>
A common configuration of the mattress 1 according to the first aspect of the present invention will be described with reference to Figures 1 to 10. The mattress 1 has a predetermined thickness in the thickness direction, and is made of a resin foam and has a substantially rectangular parallelepiped shape with a surface extending in the longitudinal and width directions. As shown in Figures 1, 2, 8, and 9, on one surface, convex portions 2 and concave portions 3 are alternately arranged in the longitudinal direction to form a plurality of rows R. In addition, convex portions 2 and concave portions 3 are alternately arranged in the width direction to form a plurality of rows L.

As shown in Figures 5 and 6, in the thickness direction, one surface side is the upper side and the opposite side is the lower side, and a support layer 6 is formed below the protrusions 2 and recesses 3. The protrusions 2 have a peak 8 that protrudes upward in the thickness direction, and are formed at an angle from the bottom 4, which is the most recessed part of the recess 3 and is adjacent to the protrusion 2, toward the peak 8. Here, the bottom 4 refers to the most recessed part of the recess 3 in the thickness direction, as shown in Figure 5 etc. Protrusions 2 include those having two or more peaks 8, and the types of protrusions 2 are classified according to the number of peaks 8, and there are multiple types of protrusions 2.

As shown in Figures 5 and 6, the distance in the thickness direction between the upper end of the apex 8 of each convex portion 2 and the bottom portion 4 is defined as the convex portion height 12. The first convex portion 2a has a convex portion height 12a, the second convex portion 2b has a convex portion height 12b, and the third convex portion 2c has a convex portion height 12c.

The apex 8 of the protrusion 2 will be described with reference to Figure 5. The difference between the protrusion 2 having one apex 8 and the protrusion 2 having multiple apexes 8 will be described. The apex 8 protrudes upward in the thickness direction of the protrusion 2, but as shown in Figure 5 (a), when there is one apex 8 (8a), the slope formed downward from the protruding tip directly reaches the bottom 4.

As shown in Figures 5(b) and 5(c), when there are multiple peaks 8 (8b, 8c), the slopes formed between adjacent peaks 8 from their tips downwards join above the bottom 4, forming a shallow valley 8d that does not reach the bottom 4. In other words, the peaks 8 are formed continuously without passing through the bottom 4. The depth 8e of the recess 8d is shallower than the convex portion height 12 (12b, 12c) and may be sufficient so long as the recess is recognizable. Furthermore, it is more preferable that the depth 8e of the recess 8d is 1/10 or more of the convex portion height 12 and 1/2 or less of the convex portion height 12.

Next, the details of the convex portion 2 will be described with reference to FIG. 4 to FIG. 6. In the convex portion 2 including a plurality of types with different numbers of apexes 8, the base length 10 facing the apex 8 in the convex portion 2 is shorter for the convex portion 2 with fewer apexes 8. To explain in detail, in the example shown in FIG. 3, etc., the apexes 8 (8b) in the second convex portion 2b are formed side by side in the direction of row R. The apexes 8 (8c) in the third convex portion 2c are formed side by side in the direction of row R. FIG. 5 is a cross-sectional view of each convex portion 2 and each recessed portion 3 when cut in the direction of row R. As shown in FIG. 5, in the longitudinal direction, the base length 10 facing the apex 8 in the convex portion 2 is shorter in the base length 10a of the first convex portion 2a than in the base length 10b of the second convex portion 2b. The base length 10b of the second convex portion 2b is shorter than in the base length 10c of the third convex portion 2c.

As shown in FIG. 5, the base 10 is the side facing the apex 8 when the protrusion 2 is substantially triangular or substantially trapezoidal. The length of the base 10 is the length connecting the tips of the most recessed bottoms 4 in the recesses 3 formed adjacent to the protrusions 2 in the longitudinal direction.

The thickness 9a of the first support layer 6a, which is the support layer 6 of the first convex portion 2a, is thicker than the thickness 9b of the second support layer 6b, which is the support layer 6 of the second convex portion 2b. The thickness 9b of the second support layer 6b is thicker than the thickness 9c of the third support layer 6c, which is the support layer 6 of the third convex portion 2c. The thickness 9 of the support layer 6 indicates the length connecting the lower surface on the opposite side to the side on which each convex portion 2 is formed in the thickness direction to the tip of the most recessed bottom portion 4 of the recess 3 adjacent to each convex portion 2.

Figure 6 also shows the same relationship as Figure 5 in the direction of row L, which is the direction along the width direction of each convex portion. In the width direction, the base 11 facing the top 8 of the convex portion 2 has a base length 11a of the first convex portion 2a that is shorter than the base length 11b of the second convex portion 2b. The base length 11b of the second convex portion 2b is shorter than the base length 11c of the third convex portion 2c. Here, the length of the base 11 is the length when the tips of the bottoms 4 of the concave portions 3 adjacent to the convex portion 2 are connected in the width direction.

To give an example of the dimensions of each part shown in FIG. 5, for example, when the thickness of the entire mattress is 80 mm and the first support layer 6a is 50 mm, the second support layer 6b is 45 mm and the third support layer 6c is 40 mm. Also, when the base length 10a is 50 mm, the base length 10b is 78 mm and the base length 10c is 105 mm. In these cases, the measured loads during compression at each convex portion 2 were as follows. The loads when the mattress 1 was compressed 25% in the thickness direction were 4.6 N for the first convex portion 2a, 7.3 N for the second convex portion 2b, and 11.5 N for the third convex portion 2c. The loads when the mattress 1 was compressed 40% in the thickness direction were 17.9 N for the first convex portion 2a, 12.5 N for the second convex portion 2b, and 19.3 N for the third convex portion 2c. The test method and test conditions are in accordance with JIS K6400-2. The load at 40% compression complies with Method A, and the load at 25% compression complies with Method D. The specific test specimen was a square with sides of 380 mm, with only one protruding portion 2 being tested, and the other protruding portions 2 were cut down to the support layer 6. This test specimen was tested in accordance with JIS K6400-2 using a pressure plate, a disk with a diameter of 200 mm.

The reason why the load of the first convex portion 2a is larger than that of the second convex portion 2b is that when compressed by about 40%, it has already reached the area of the first support layer 6a, and the load measured is the load of the first support layer 6a, not the load of the first convex portion 2a itself. When compressed by about 40%, the second convex portion 2b and the third convex portion 2c have not yet reached their respective support layers 6. These measured values are only examples, and the measured values will vary depending on the material of the sheet material 25 used, etc.

These experimental results show that when comparing the first to third convex portions 2a to 2c, there are the following differences in characteristics in the initial sinking state (25% compression). The first convex portion 2a has the smallest repulsive force when the user first touches it. At low compression, the repulsive force is small, so the initial touch is soft, giving a soft feeling to the body. Conversely, the third convex portion 2c has the largest repulsive force when the user first touches it. Therefore, the third convex portion 2c is suitable for areas where the body pressure is high. The second convex portion 2b has intermediate properties between the first convex portion 2a and the third convex portion 2c. This difference in characteristics is caused by the difference in the length of the base 10 in the longitudinal direction. In addition, there is also a difference in characteristics caused by the difference in the number of apexes 8.

In addition, there is another characteristic difference when comparing the first convex portion 2a to the third convex portion 2c. When the user uses it, the following characteristics are obtained when the body pressure is applied and the mattress is in a sunk state (40% compressed). The first convex portion 2a has a strong resilience due to the thickness of the first support layer 6a, and supports the body and maintains the rigidity of the entire mattress 1. The third convex portion 2c has the largest resilience due to the synergistic effect between the thickness of the third support layer 6c and the third convex portion 2c, so it supports the body more and contributes to the rigidity of the entire mattress 1. Therefore, it is suitable for the first zone Z1 and the seventh zone Z7, which are the ends of the mattress 1. The second convex portion 2b has the smallest resilience of the three types. Since a certain degree of softness is maintained even when the body is in a sunk state, if it is placed in the zone Z corresponding to the lower back and thighs, or the shoulders and calves, it can be a factor that facilitates the initial compression rotation of turning over.

Next, the positional relationship between the convex portions 2 and the concave portions 3 will be described with reference to Figures 1 to 4, 8 and 9. On at least one surface of the mattress 1, the convex portions 2 and the concave portions 3 are arranged in a staggered manner, shifted from each other in the longitudinal and width directions.

As shown in FIG. 1 etc., rows L are formed in the width direction, with the same types of convex portions 2 and concave portions 3 arranged alternately in each row L. On at least one surface of the mattress 1, in both columns R and rows L, convex portions 2 and concave portions 3 are arranged alternately, concave portions 3 are formed at positions adjacent to convex portions 2 in the longitudinal and width directions, and convex portions 2 are formed at positions adjacent to concave portions 3 in the longitudinal and width directions.

As shown in FIG. 1 etc., the mattress 1 is divided into a number of zones Z (Z1 to Z7) in the longitudinal direction. In the longitudinal direction, the types of the protrusions 2 in adjacent zones Z are different from each other.

As shown in Figures 1 to 10, the types of convex portions 2 in each zone Z include at least two of the three types: a first convex portion 2a having one apex 8 (8a), a second convex portion 2b having two apexes 8 (8b), and a third convex portion 2c having three apexes 8 (8c).

The protrusions 2 include protrusions 2 that have at least two or more consecutive peaks 8 formed without passing through the bottom 4. Although Figs. 1 and 5 show protrusions 2 in which the peaks 8 are formed continuously in the longitudinal direction, the protrusions 2 may have peaks 8 formed continuously in the width direction of the mattress 1.

Next, the recess 3 will be described with reference to FIG. 1 to FIG. 10. The recess 3 includes recesses having two or more bottoms 4, and the types of the recess 3 are classified according to the number of bottoms 4 corresponding to the types of the protrusions 2, and there are multiple types of the recess 3. The bottoms 4 are formed continuously without passing through the tops 8. Specifically, the recess 3 includes at least two of the three types of the first recess 3a, the second recess 3b, and the third recess 3c. As shown in FIG. 5, etc., in at least one longitudinal direction, the first recess 3a is adjacent to the first protrusion 2a, the second recess 3b is adjacent to the second protrusion 2b, and the third recess 3c is adjacent to the third protrusion 2c. In the longitudinal direction, the second recess 3b has two bottoms 4b (4), and the third recess 3c has three bottoms 4c (4). The bottoms 4b and 4c are both formed continuously without passing through the tops 8.

In addition, the types of protrusions 2 in adjacent zones Z (Z1 to Z7) in the longitudinal direction are different from each other. The type of protrusion 2 to be selected in each zone Z is selected according to the body pressure to be received by each part of the user's body.

As shown in FIG. 1 etc., the rows R are formed along the longitudinal direction, and each row R includes multiple types of protrusions 2 and recesses 3. As shown in FIG. 3, there are three types of protrusions 2 and recesses 3, and each row R includes at least two of these types. Mattresses 1a and 1b described below each show an example including three types of protrusions 2 and recesses 3, but may be configured with two types. The protrusions 2 include protrusions 2 with at least two or more peaks 8 (continuously formed).

Figure 3(a) shows a first convex portion 2a, with one apex 8 (8a) formed on the upper side in the thickness direction. Figure 3(b) shows a second convex portion 2b, with two apexes 8 (8b) formed consecutively on the upper side in the thickness direction without passing through the bottom 4. Figure 3(c) shows a third convex portion 2c, with three apexes 8 (8c) formed consecutively on the upper side in the thickness direction without passing through the bottom 4. Details will be described later, but as shown in Figure 1 etc., in adjacent zones Z, different types of convex portions 2 out of three types are formed.

3, 5, and 6, the apex 8 is a portion of the convex portion 2 that protrudes upward in the thickness direction. As shown in FIG. 3(a), the apex 8 is integrally formed with the first convex portion 2a. As shown in FIG. 3(b), 3(c), 5(b), and 5(c), the apex 8 of the second convex portion 2b and the third convex portion 2c protrudes partially upward in the thickness direction, and a recess 8d is formed between the apex 8 (for example, between the apex 8b and the apex 8b). In FIG. 3, etc., the boundary between the convex portion 2 and the apex 8 and the boundary between the surfaces having different orientations in the apex 8 are shown as ridge lines, but in reality, the ridge lines may be unclear. As shown in FIG. 1, etc., seven zones Z are shown as examples, Z1 to Z7, but the number of zones Z is not limited to seven, and any number of zones Z can be formed.

The convex portion 2 may have the following relationship from the first convex portion 2a to the third convex portion 2c. In Figs. 5 and 6, the height of the convex portion 2 in the thickness direction plus the thickness 9 of the support layer 6 may be such that the third convex portion 2c is higher than the second convex portion 2b, and the second convex portion 2b is higher than the first convex portion 2a. Additionally, the depth of the recess 3 corresponding to the convex portion height 12 may be such that the third recess 3c is deeper than the second recess 3b, and the second recess 3b is deeper than the first recess 3a. In this case, the mattress 1 is formed with different heights of the recesses for each zone Z.

<Common effects for all mattresses>
As described above, the common configuration of the mattress 1 solves the following problems and provides the following effects. In conventional mattresses, the hardness can be varied by changing the depth and arrangement pitch of the grooves, but it is difficult to form fine differences in hardness. Since the surface of the base body is only formed with a plurality of grooves, there is a flat surface between the grooves, and even if the flat surface can be rebound in the thickness direction, there is a problem that a force is required to rotate the body when the user turns over. In addition, in other conventional mattresses, a three-dimensional curved uneven surface is formed on the mat surface, but the uneven surface shape is limited, and the types of shapes that can be formed are limited. The mattress 1 solves these problems.

As shown in FIG. 1, the mattress 1 has a row R in which the convex portions 2 and the concave portions 3 are alternately arranged, and the convex portions 2 are made up of a plurality of types each including two or more peaks 8. That is, the convex portions 2 arranged in the longitudinal and transverse directions include those having two or more peaks 8, and are made up of convex portions 2 with different numbers of peaks 8, so that a variety of surface shapes can be formed and the hardness can be adjusted. Therefore, the mattress 1 can flexibly set the hardness according to the difference in the body pressure of the user's body parts. Also, on one surface, the row R is formed by alternating convex portions 2 having two or more peaks 8 and concave portions 3 in the longitudinal direction, and the row L is formed by alternating convex portions 2 and concave portions 3 in the transverse direction. When the user turns over in his/her sleep, the concave portions 3 induce the rotation of the axis of the body accompanying the turn, and the slope of the convex portion 2 is compressed while a repulsive force is generated in the direction intersecting the slope, thereby holding the body. Therefore, the rotational force of the axis of the body can be assisted.

In addition, in the mattress 1, in the convex portion 2 including multiple types with different numbers of peaks 8, the base length 10 facing the peaks 8 in the convex portion 2 may be shorter for the convex portion 2 with fewer peaks 8. In this case, the difference in the base length 10 corresponding to the type of convex portion 2 can provide different hardness and hardness characteristics.

There is also a demand for the mattress 1 to support body pressure even when the user moves, such as by turning over in bed. In other words, it is required to support body pressure evenly within a certain range. In response to this, the surface of the mattress 1 has convex portions 2 and concave portions 3 arranged alternately in the longitudinal and transverse directions, so that it is possible to form approximately uniform hardness and hardness characteristics within each zone Z. Therefore, body pressure can be received approximately evenly within each zone Z.

In addition, since the body pressure of the mattress 1 varies depending on the part of the user's body, there is a demand for the mattress 1 to have different hardness and hardness characteristics depending on the corresponding part of the body. In response to this, the mattress 1 is divided into multiple zones Z in the longitudinal direction, and the convex parts 2 and concave parts 3 of adjacent zones Z are configured by a combination of at least two types out of three types. The mattress 1 can be formed into many types of surface shapes, and the hardness of each zone Z can be adjusted. Therefore, the mattress 1 can flexibly set the hardness of each zone Z according to the difference in the load of the user's body parts. In addition, on one surface, the convex parts 2 and concave parts 3 are alternately arranged in the longitudinal direction to form multiple rows R, so that when the user turns over in his sleep, the force is reduced by the support of the convex parts 2.

The mattress 1 is required to appropriately support the body pressure of the user by forming different hardness for each zone Z in the surface shape formed in each zone Z. In response to this, the mattress 1 has a different number of peaks 8 in each convex portion 2 in the direction of row R, so that a different hardness can be formed for each zone Z. The length of the base 10 increases from the base length 10a of the first convex portion 2a to the base length 10c of the third convex portion 2c, and the thickness of the support layer 6 decreases from the first convex portion 2a to the third convex portion 2c.

Therefore, different hardness can be formed by combining the support layer 6 with each of the protrusions 2 depending on the type of protrusion 2. The longer the base 10 of the protrusion 2, the greater the predetermined repulsive force in the initial state when the user makes contact, and the thicker the support layer 6, the more firmly it supports the user's body pressure, so each protrusion 2 can have a different hardness.

In addition, by including multiple types of protrusions 2, not only is there a difference in hardness, but the following hardness characteristics have an effect. When used by a user, the first protrusions 2a have a low-load resilience, i.e. a soft touch, in the initial state when they come into contact with the mattress 1, and they flexibly deform to accommodate small initial loads, providing high drapeability (the ability to fit along the contours of the body). When compressed under a higher load, they are able to firmly support body pressure against that load. After sinking, the resilience increases, providing the effect of firmly supporting body pressure. They are suitable for use on body parts that experience high body pressure, such as the buttocks.

On the other hand, the third convex portion 2c has a high resilience, i.e. a firm touch, from the initial state when it comes into contact with the mattress 1, and even after it sinks in, the change in resilience is small, which has the effect of firmly supporting body pressure. It is suitable for body parts where body pressure is low, such as the head. In other words, the hardness characteristic is not only the steady hardness in a sunk state, but also the characteristic resulting from the hardness that changes in the process from when the user first comes into contact with the mattress to when it sinks in.

Mattress 1 is also required to allow the user to turn over more smoothly. In response to this, mattress 1 has the effect of reducing the force required when the user turns over. In detail, as shown in FIG. 1 etc., in row R, convex portion 2 includes at least one of a second convex portion 2b having a base 10b and two tops 8b lined up in a row along the longitudinal direction, or a third convex portion 2c having a base 10c and three tops 8c lined up in a row.

With this configuration, in row R, when the user turns over in their sleep, the repulsive force of the convex portion 2 against the pressure from the body in the width direction is greater than when the convex portion 2 is composed of only the first convex portion 2a. When the user turns over in their sleep, the slope of the convex portion 2 adjacent to the recessed portion 3 in the width direction is compressed, and a repulsive force is generated in the direction intersecting the slope to support the body. This allows the user to turn over more easily.

Furthermore, as described with reference to Figures 5 and 6, if the height of the convex portion 2, which is the sum of the convex portion height 12 and the thickness 9 of the support layer 6, and the depth of the concave portion 3 corresponding to the convex portion height 12, are configured to differ depending on the type of convex portion 2, the height of the convexities and recesses is formed to be different for each zone Z. In this case, since the shape of the back of the body is a continuous gentle curve, the mattress 1 can improve its drapeability by changing the height of the convexities and recesses for each zone Z.

<About the workability of Mattress 1>
Next, the processability common to the mattress 1 will be described with reference to Figures 5 and 6. The mattress 1 has a shape that allows two mattresses 1 to be processed from one sheet material 25 during manufacturing. The specific manufacturing device and manufacturing method will be described later, but the reason why such processing is possible will be described.

As shown in FIG. 5, the mattress 1 has a convex portion 2 adjacent to a concave portion 3 in the width direction, and the convex portion 2 and the concave portion 3 are symmetrical with respect to a first imaginary line 13a that is parallel to the longitudinal direction and passes through the center between the tip of the top portion 8 and the bottom portion 4. In detail, as shown in FIG. 5, the first convex portion 2a and the first concave portion 3a, the second convex portion 2b and the second concave portion 3b, and the third convex portion 2c and the third concave portion 3c are symmetrical with respect to the first imaginary line 13a that is parallel to the longitudinal direction and passes through the center between the tip of the top portion 8 and the bottom portion 4. That is, the shape of the top portion 8 in each convex portion 2 forms a concave portion 3 that is symmetrical with respect to the first imaginary line 13a. For example, as shown in FIG. 5(b), the second concave portion 3b adjacent to the second convex portion 2b has two bottom portions 4b that are symmetrical with respect to the two top portions 8b. The third concave portion 3c adjacent to the third convex portion 2c also has three bottom portions 4c. Since the convex portion 2 and concave portion 3 of the mattress 1 have the above shapes, they have a symmetrical shape when the concave and convex surfaces of the two mattresses 1 are placed facing each other in the longitudinal direction.

Furthermore, as shown in FIG. 6, in the width direction of the mattress 1, the first convex portion 2a is adjacent to the first concave portion 3a, the second convex portion 2b is adjacent to the second concave portion 3b, and the third convex portion 2c is adjacent to the third concave portion 3c. The shape is symmetrical with respect to a second imaginary line 13b that is parallel to the width direction and passes through the center between the tip of the top portion 8 and the bottom portion 4. Since the convex portions 2 and concave portions 3 in the mattress 1 have the above shapes, when the concave and convex surfaces of two mattresses 1 are placed face to face, they have a symmetrical shape in both the longitudinal direction and the width direction.

<Effect of processability of mattress 1>
For production efficiency and material cost reduction, it is required that two mattresses 1 can be processed simultaneously from one sheet material 25. In response to this, the convex portion 2 and the concave portion 3 are formed symmetrically with respect to the first imaginary line 13a in the longitudinal direction, so that body pressure can be distributed and supported. In addition, since the convex portion 2 and the concave portion 3 are symmetrically with respect to the first imaginary line 13a, two mattresses 1 of the same shape can be formed from one sheet material 25 by a specific processing method. Therefore, it is possible to improve production efficiency and reduce material costs while maintaining body pressure dispersion.

As shown in Figures 5 and 6, the mattress 1 may have a shape in which the convex portions 2 and concave portions 3 are symmetrical with respect to both the first imaginary line 13a and the second imaginary line 13b. In this case, the shape of the mattress 1 becomes more symmetrical in both the longitudinal and width directions, making it easier to form two mattresses 1 of the same shape from a single sheet material 25 using a specific processing method. In addition, the mattress 1 has the convex portions 2 and concave portions 3 formed at equal intervals in the width direction, so it can also distribute and support body pressure.

<Configuration of mattress 1a of first embodiment>
Next, the configuration of a mattress 1a according to a first embodiment of the first aspect of the present invention will be described with reference to Figures 1, 2, and 7. The seven zones Z of the mattress 1a, the first zone Z1 to the seventh zone Z7, are arranged in order from one end to the other end in the longitudinal direction. The types of the convex parts 2 in the zones Z are as follows: the first zone Z1 and the seventh zone Z7 are the third convex parts 2c, the second zone Z2 and the sixth zone Z6 are the first convex parts 2a, the third zone Z3 and the fifth zone Z5 are the second convex parts 2b, and the fourth zone Z4 is the first convex part 2a.

The relationship between the zones Z and each part of the user's body will be described with reference to FIG. 7. The first zone Z1 corresponds to the head. The second zone Z2 corresponds to the shoulders, and the third zone Z3 corresponds to the waist. The fourth zone Z4 corresponds to the buttocks. The fifth zone Z5 corresponds to the thighs, the sixth zone Z6 corresponds to the calves, and the seventh zone Z7 corresponds to the heels. When the user lies on the mattress 1a, the proportions of body pressure in each part of the body are approximately 8% for the head, approximately 33% for the shoulders, approximately 44% for the buttocks, and approximately 15% for the calves.

In mattress 1a, the head corresponds to the third convex portion 2c, the shoulders to the first convex portion 2a, the waist to the second convex portion 2b, the buttocks to the first convex portion 2a, the thighs to the second convex portion 2b, the calves to the first convex portion 2a, and the heels to the third convex portion 2c. The head and heels, which experience relatively low body pressure, correspond to the third convex portion 2c, while the shoulders and buttocks, which experience high body pressure, correspond to the first convex portion 2a. The waist and thighs, which experience intermediate body pressure, correspond to the second convex portion 2b.

<Effects of the mattress 1a of the first embodiment>
As described above, the mattress 1a of the first embodiment has the following effects. The mattress 1a is required to have a moderate hardness while having a moderate flexibility according to the body part of the user. In contrast, the mattress 1a has a certain repulsive force at the beginning and supports body pressure after being compressed to a certain degree because the first zone Z1 and the seventh zone Z7, which are the zones Z at both ends in the longitudinal direction, are the third convex parts 2c. The second zone Z2 and the fifth zone Z5 are the first convex parts 2a, so they have a small initial repulsive force, flexibly deform to a small initial load, and have high drapeability. When compressed with a higher load, they can firmly support body pressure against that load. The third zone Z3 and the fifth zone Z5 are the second convex parts 2b, so they have an intermediate initial repulsive force, and after compression, they can firmly support body pressure next to the second zone Z2 and the sixth zone Z6. Furthermore, the fourth zone Z4 is the first convex part 2a, so it shows the same characteristics as the second zone Z2, etc. Therefore, the body pressure according to the body part of the user can be supported according to the appropriate hardness characteristics of each zone Z.

<Configuration of mattress 1b of second embodiment>
Next, the configuration of a mattress 1b of a second embodiment according to the first aspect of the present invention will be described with reference to Figures 8 to 11. The seven zones Z of the mattress 1b, the first zone Z1 to the seventh zone Z7, are arranged in order from one end to the other end in the longitudinal direction. The types of the convex parts 2 in the zones Z are as follows: the first zone Z1 and the seventh zone Z7 are the third convex part 2c; the second zone Z2 and the sixth zone Z6 are the second convex part 2b, the third zone Z3 and the fifth zone Z5 are the third convex part 2c, and the fourth zone Z4 is the first convex part 2a.

Referring to FIG. 10, the relationship between the zones Z and each part of the user's body will be described. The first zone Z1 corresponds to the head. The second zone Z2 corresponds to the shoulders, and the third zone Z3 corresponds to the lower back. The fourth zone Z4 corresponds to the buttocks. The fifth zone Z5 corresponds to the thighs, the sixth zone Z6 corresponds to the calves, and the seventh zone Z7 corresponds to the heels. When the user lies on the mattress 1a, the proportion of body pressure in each part of the body is as described above.

As shown in FIG. 10, in mattress 1b, the head corresponds to third convex portion 2c, the shoulders to second convex portion 2b, the lower back to third convex portion 2c, the buttocks to first convex portion 2a, the thighs to third convex portion 2c, the calves to second convex portion 2b, and the heels to third convex portion 2c. The head and heels, which have relatively low body pressure, correspond to third convex portion 2c, and the buttocks, which have high body pressure, correspond to first convex portion 2a. The second zone Z2 (corresponding to the shoulders) and sixth zone Z6 (corresponding to the calves), which are zones Z sandwiched between third convex portions 2c, correspond to second convex portion 2b. The hardness and hardness characteristics of each convex portion 2 are as described above.

Furthermore, in mattress 1b, a row L including a first convex portion 2a may be formed at any of the boundaries with each zone Z. In detail, as shown in FIG. 10, in mattress 1b, a row L may be formed by a first convex portion 2a and a first concave portion 3a at the boundaries between second zone Z2 and third zone Z3 and between fifth zone Z5 and sixth zone Z6.

In addition, in at least some rows L of the mattress 1b, the convex portion 2 and the specific convex portion 2d whose top 8 is lower than the convex portion 2 may be adjacent to each other across the concave portion 3, forming a height pattern H in which the convex portion 2 and the specific convex portion 2d are successively changed in height. In detail, as shown in FIG. 11(a), in at least some rows L of the mattress 1b, the third convex portion 2c which is the convex portion 2 and the specific convex portion 2d whose top 8 is lower than the third convex portion 2c may be adjacent to each other across the concave portion 3, forming a height pattern H in which the convex portion 2 and the specific convex portion 2d are successively changed in height. The top 8 of the convex portion 2 and the top 8 of the specific convex portion 2d have a height difference h. Furthermore, in regard to the concave portion 3, a specific concave portion 3d whose depth is shallower than the third concave portion 3c is formed in association with the height pattern H.

As shown in FIG. 11(a), in row L, the third convex portion 2c and the specific convex portion 2d are alternately formed, and the third recessed portion 3c and the specific recessed portion 3d are also alternately formed. For example, from left to right in the drawing, the third convex portion 2c, the specific recessed portion 3d, the specific convex portion 2d, and the third recessed portion 3c are repeatedly formed in this order. Note that the order of the specific convex portion 2d and the third recessed portion 3c may be reversed, for example, the third recessed portion 3c may be formed to the right of the third convex portion 2c. The reason that the specific recessed portion 3d and the third recessed portion 3c are alternately formed is to perform so-called wave-splitting processing, in which two cushion bodies 19 are simultaneously processed from one sheet material 25, as described later.

Figures 11(b) and 11(c) show the state when the user turns over in bed. When the user turns over in bed, part of the body rides up onto the specific protrusion 2d, which is lower by the height difference h, and is supported by the protrusion 2, which is higher by the height difference h than the specific protrusion 2d. The situation is the same when the user turns over to one side and when the user turns over to the other side.

Furthermore, when the type of the convex portion 2 includes a third convex portion 2c, the height pattern H may be formed in any of the third convex portions 2c formed in the longitudinal direction. As shown in Figs. 10 and 11, the mattress 1b may have the height pattern H formed in the following parts. In the third zone Z3, the third convex portion 2c adjacent to the second zone Z2 and the fourth zone Z4. In the fifth zone Z5, the third convex portion 2c adjacent to the fourth zone Z4 and the sixth zone Z6. In the first zone Z1, the third convex portion 2c in the even-numbered rows in the direction from the boundary with the second zone Z2 toward the first zone Z1. In the seventh zone Z7, the third convex portion 2c in the even-numbered rows in the direction from the boundary with the sixth zone Z6 toward the seventh zone Z7.

<Effects of the mattress 1b of the second embodiment>
As described above, the mattress 1b of the second embodiment has the following advantages. Like the mattress 1a, the mattress 1b is required to have appropriate hardness while having appropriate flexibility according to the body part of the user.

In contrast, the mattress 1b has third convex parts 2c in the zones Z at both ends in the longitudinal direction, the first zone Z1 and the seventh zone Z7, and the third zone Z3 and the fifth zone Z5, so that they have a certain initial resilience and support body pressure after being compressed to a certain degree. The fourth zone Z4 is the first convex part 2a, so it has a small initial resilience and flexibly deforms to accommodate small initial loads and has high drapeability. When compressed under a higher load, it can firmly support body pressure against that load. The second zone Z2 and the sixth zone Z6, whose adjacent zones Z are composed of the third convex part 2c, are the second convex part 2b, so they exhibit intermediate characteristics between the first convex part 2a and the third convex part 2c.

This allows for a gradual change in hardness from the first zone Z1 to the third zone Z3, and from the fifth zone Z5 to the seventh zone Z7, without any sudden changes. Furthermore, since the fourth zone Z4 is the first convex portion 2a, it exhibits the characteristics described above. Therefore, the user's body pressure can be supported according to the hardness characteristics of each zone Z.

In addition, the mattress 1b is required to mitigate the sudden change in hardness at the boundary of the zone Z. In response to this, the mattress 1b may further have a row L including the first convex portion 2a formed at any of the boundaries with each zone Z. In this case, the boundary with the zone Z where the row L including the first convex portion 2a is formed can buffer the sudden change in hardness and disperse the body pressure. In detail, as shown in FIG. 10, the row L may be formed by the first convex portion 2a and the first recess 3a at the boundary between the second zone Z2 and the third zone Z3 and the boundary between the fifth zone Z5 and the sixth zone Z6. In this case, the row L is formed by the first convex portion 2a and the first recess 3a at the boundary between the second zone Z2 and the third zone Z3 and the boundary between the fifth zone Z5 and the sixth zone Z6, and therefore can buffer the sudden change in hardness and disperse the body pressure.

Mattress 1b is also required to allow the user to turn over more easily. In response to this, as shown in FIG. 11, mattress 1b may have a height pattern H in which protrusions 2 and specific protrusions 2d whose apex 8 is lower by h are adjacent to each other across recesses 3 in at least some rows L, and the protrusions 2 and specific protrusions 2d alternate in height.

In this case, in the direction of row L, the convex portion 2 and the specific convex portion 2d form a height pattern H, making it easier to turn over in your sleep. When the user turns over in their sleep, the axis of the body is induced to rotate with the turning over by the recessed portion 3 as well as the specific convex portion 2d. Furthermore, while the slope of the convex portion 2 adjacent to the specific convex portion 2d across the recessed portion 3 in the width direction is compressed, a repulsive force is generated in the direction intersecting the slope to support the body. Therefore, the mattress 1b can better support the turning force of the axis of the body, providing the special effect of allowing the user to turn over more easily.

In other words, when the user turns over in their sleep, they can easily move in the width direction between the recess 3 and the specific protrusion 2d part of the protrusion 2 that is lower by the height difference h. Furthermore, after the movement, the user is received by the part of the protrusion 2 that is higher than the specific protrusion 2d by the height difference h, so the state after turning over can be maintained. Therefore, the user can easily turn over, and the state after turning over can be easily maintained.

Mattress 1b is also required to be configured to allow the user to easily move the entire body when turning over in an appropriate position in zone Z, and to maintain a certain degree of movement. In contrast, when mattress 1b includes third convex portions 2c as a type of convex portion 2, height pattern H may be formed in any of the third convex portions 2c formed in the longitudinal direction. In this case, height pattern H is formed in third convex portion 2c, which strongly repels body pressure from the width direction, making it easier for the user to turn over.

In other words, the mattress 1b has a height pattern H formed in the third convex portion 2c, which has the greatest repulsive force against body pressure from the width direction, so the user can maintain the position after turning over and turn over easily. Also, as shown in Figure 10, the height patterns H are formed at positions dispersed in the longitudinal direction, so that the mattress can evenly repel body pressure from the width direction according to the height of the user.

<Cushion body manufacturing method>
Next, a method for manufacturing a cushion body according to the second embodiment of the present invention will be described. The cushion body 19 is used not only for the mattress 1 of the present invention but also as a cushion for a seat cushion, a chair, a sofa, etc.

The manufacturing method of the cushion body 19 will be described with reference to Figure 12. The cushion body manufacturing device 20 used in the manufacturing method of the cushion body 19 is a so-called wave-splitting processing device, which is a device that simultaneously manufactures two cushion bodies 19 with the same surface shape from one sheet material 25. The cushion body manufacturing device 20 includes a roller 22 on which multiple disks 21 are stacked in the axial direction and which can rotate around the axis C, and a cutting means 24 that cuts the sheet material 25, which is the material of the cushion body 19.

Here, the cushion body 19 will be described using an example in which it is used with the mattress 1. The cushion body 19 has a predetermined thickness in the thickness direction, and on one surface, convex parts 2 (corresponding to convex parts 2 of the mattress 1) and concave parts 3 (corresponding to concave parts 3 of the mattress 1) are arranged alternately. The convex parts 2 have a peak 8 (corresponding to the peak 8 of the mattress 1) that protrudes upward in the thickness direction, and are formed at an angle from a bottom part 4 (corresponding to the bottom 4 of the mattress 1), which is the most recessed part of the concave part 3 and adjacent to the convex part 2, toward the peak 8, and the convex parts 2 include those having two or more peaks 8. The types of the convex parts 2 are classified according to the number of peaks 8, and there are multiple types of the convex parts 2.

The disk 21 has a number of roller protrusions 26 and roller recesses 27 arranged alternately along the circumferential direction on its outer circumferential surface. As shown in FIG. 12, the rollers 22 form roller pairs 23 in which the roller protrusions 26 and roller recesses 27 are arranged in parallel so that they correspond to each other in a staggered manner. The rollers 22 use multiple types corresponding to the types of protrusions 2 and recesses 3 in the cushion body 19 by stacking multiple disks 21 in the axial direction.

Taking the cushion body 19 used in the mattress 1 as an example, the rollers 22 are made up of at least two types corresponding to the types of protrusions 2 and recesses 3. As shown in FIG. 12, the rollers 22 are fixed to a rotating shaft 28 that forms an axis C. A motor (not shown) is connected to the rotating shaft 28 via a transmission mechanism such as gears (not shown). As will be described later, the rollers 22 are synchronously rotated by the motor in the direction of the arrow shown in FIG. 12, whereby the sheet material 25 is sent out in one direction. Note that the spacing is exaggerated in FIG. 12.

Next, the procedure for manufacturing the cushion body 19 will be described. The method for manufacturing the cushion body 19 uses the cushion body manufacturing device 20 already described. The sheet material 25 is inserted between the roller pair 23 of the cushion body manufacturing device 20, and is fed in one direction by a motor while being compressed between the roller convex portion 26 and the roller concave portion 27. The sheet material 25 is cut and separated by the cutting means 24 between the roller pair 23 on the sending side before elastic recovery, and the convex portion 2 and the concave portion 3 are formed on the cut surface side of the sheet material 25. The convex portion 2 includes types with different numbers of peaks 8. The direction in which the sheet material 25 is fed corresponds to the width direction of the mattress 1.

<Effects of the cushion body manufacturing method>
As described above, the manufacturing method of the cushion body 19 has the following effects. Conventionally, a so-called wave-splitting processing device has been proposed as a manufacturing device for a cushion body. However, no manufacturing method capable of manufacturing the cushion body 19 used in the mattress 1 according to the first aspect of the present invention has been proposed. In contrast, the cushion body manufacturing device 20 used in the cushion body manufacturing method forms a pair of rollers 23 corresponding to the surface shape of the cushion body 19 to be processed. Therefore, when the cushion body manufacturing device 20 is used and the sheet material 25 is inserted between the pair of rollers 23 along the width direction, the convex portion 2 and the concave portion 3 can be formed sequentially in line in the portion corresponding to the roller 22.

As shown in FIG. 12, two cushion bodies 19 for use in a mattress 1 are simultaneously formed in the thickness direction of the sheet material 25, with the cutting means 24 sandwiched between them. This makes it possible to manufacture cushion bodies 19 that have convex portions 2, including types with different numbers of apexes 8, and concave portions 3 formed on the cut surface side of the sheet material 25. In addition, the amount of sheet material 25 that is discarded is minimized.

The cushion body manufacturing device 20 and the cushion body manufacturing method described above have been described with reference to an example in which the cushion body 19 is used for a mattress 1, but this is not limited thereto, and it can of course be applied to cushions for seat cushions, chairs, sofas, and other cushions.

Reference Signs List 1, 1a, 1b Mattress 2 Convex portion 2a First convex portion 2b Second convex portion 2c Third convex portion 2d Specific convex portion 3 Concave portion 4, 4b, 4c Bottom portion 6 Support layer 8, 8b, 8c Top portion 9, 9a, 9b, 9c Thickness of support layer 10, 10a, 10b, 10c Base 13a First imaginary line 19 Cushion body 21 Disk 22 Roller 23 Roller pair 24 Cutting means 25 Sheet material 26 Roller convex portion 27 Roller concave portion C Axis line H Height pattern L Row R Column Z Zone

Claims (7)

A substantially rectangular parallelepiped mattress made of a resin foam having a predetermined thickness in a thickness direction, a surface extending in a longitudinal direction and a width direction,
On one surface, a plurality of rows are formed by alternately arranging protrusions and recesses in the longitudinal direction, and a plurality of rows are formed by alternately arranging the protrusions and recesses in the width direction,
In the thickness direction, one surface side is defined as an upper side and the other surface side is defined as a lower side, and a support layer is formed below the protrusions and the recesses,
the protrusion has an apex protruding upward in the thickness direction, and is formed to be inclined from a bottom portion which is the most recessed portion of the recess and is adjacent to the protrusion toward the apex,
The convex portion includes a convex portion having two or more apexes,
The types of the protrusions are classified according to the number of the apexes,
The convex portions are of a plurality of types ,
The longitudinal direction is divided into a plurality of zones,
In the longitudinal direction, the types of the protrusions in the adjacent zones are different from each other,
The mattress is divided into seven zones . The zone at the center in the longitudinal direction is formed with a first convex portion having one apex,
And/or the mattress according to claim 1, wherein the zones at both ends in the longitudinal direction are each formed with a third convex portion having three peaks . A substantially rectangular parallelepiped mattress made of a resin foam having a predetermined thickness in the thickness direction, a surface extending in the longitudinal direction and the width direction,
On one surface, a plurality of rows are formed by alternately arranging protrusions and recesses in the longitudinal direction, and a plurality of rows are formed by alternately arranging the protrusions and recesses in the width direction,
In the thickness direction, one surface side is defined as an upper side and the other surface side is defined as a lower side, and a support layer is formed below the protrusions and the recesses,
the protruding portion has an apex protruding upward in the thickness direction, and is formed to be inclined from a bottom portion which is the most recessed portion of the recess and is adjacent to the protruding portion toward the apex,
The convex portion includes a convex portion having two or more apexes,
The types of the protrusions are classified according to the number of the apexes,
The convex portions are of a plurality of types,
The longitudinal direction is divided into a plurality of zones,
In the longitudinal direction, the types of the protrusions in the adjacent zones are different from each other,
The types of the protrusions in each of the zones are as follows:
a first protruding portion having one apex;
a second protruding portion having two apexes;
At least two types of the three types of third protrusions having three peaks are included,
A mattress in which the third convex portion is formed in both zones at both ends in the longitudinal direction. The mattress according to claim 3 , wherein the first convex portion is formed in the central zone in the longitudinal direction. The types of the protrusions in each of the zones are as follows:
The mattress according to claim 3 or 4, comprising three types of convex portions: the first convex portion, the second convex portion, and the third convex portion. A substantially rectangular parallelepiped mattress made of a resin foam having a predetermined thickness in the thickness direction, a surface extending in the longitudinal direction and the width direction,
On one surface, a plurality of rows are formed by alternately arranging protrusions and recesses in the longitudinal direction, and a plurality of rows are formed by alternately arranging the protrusions and recesses in the width direction,
In the thickness direction, one surface side is defined as an upper side and the other surface side is defined as a lower side, and a support layer is formed below the protrusions and the recesses,
the protruding portion has an apex protruding upward in the thickness direction, and is formed to be inclined from a bottom portion which is the most recessed portion of the recess and is adjacent to the protruding portion toward the apex,
The convex portion includes a convex portion having two or more apexes,
The types of the protrusions are classified according to the number of the apexes,
The convex portion is of a plurality of types,
The longitudinal direction is divided into a plurality of zones,
In the longitudinal direction, the types of the protrusions in the adjacent zones are different from each other,
The types of the protrusions in each of the zones are as follows:
a first protruding portion having one apex;
a second protruding portion having two apexes;
The third projection includes only two types of the three types of the three peaks,
The zone in the central portion in the longitudinal direction is a mattress in which the first convex portion is formed. A substantially rectangular parallelepiped mattress made of a resin foam having a predetermined thickness in the thickness direction, a surface extending in the longitudinal direction and the width direction,
On one surface, a plurality of rows are formed by alternately arranging protrusions and recesses in the longitudinal direction, and a plurality of rows are formed by alternately arranging the protrusions and recesses in the width direction,
In the thickness direction, one surface side is defined as an upper side and the other surface side is defined as a lower side, and a support layer is formed below the protrusions and the recesses,
the protruding portion has an apex protruding upward in the thickness direction, and is formed to be inclined from a bottom portion which is the most recessed portion of the recess and is adjacent to the protruding portion toward the apex,
The convex portion includes a convex portion having two or more apexes,
The types of the protrusions are classified according to the number of the apexes,
The convex portion is of a plurality of types,
The longitudinal direction is divided into a plurality of zones,
In the longitudinal direction, the types of the protrusions in the adjacent zones are different from each other,
The types of the protrusions in each of the zones are as follows:
a first protruding portion having one apex;
a second protruding portion having two apexes;
At least two types of the three types of third protrusions having three peaks are included,
When the type of the convex portion includes the third convex portion, in any of the third convex portions formed in the longitudinal direction, the convex portion and a specific convex portion whose top height is lower than that of the convex portion are adjacent to each other across the recess, and a height pattern in which the convex portion and the specific convex portion sequentially alternate in height is formed.

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