JP2006097223A - Three-dimensional network structure and method for producing three-dimensional network structure - Google Patents
Three-dimensional network structure and method for producing three-dimensional network structure Download PDFInfo
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/122—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with special fibres, such as acrylic thread, coconut, horsehair
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/121—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with different inlays
Abstract
Description
本発明は、体圧分散性の優れた立体網状構造体及び立体網状構造体の製造方法に関する。 The present invention relates to a three-dimensional network structure having excellent body pressure dispersibility and a method for producing a three-dimensional network structure.
従来、立体網状構造体で形成されたクッション材が知られている。該立体網状構造体は、樹脂材料により長尺に連続した連続線条が多数本立体的に不規則に絡み合って、その相互の接触部が溶着され、連続線条間に所定の空隙率の空隙を有して弾性を有するものである。 Conventionally, a cushion material formed of a three-dimensional network structure is known. The three-dimensional network structure has a plurality of continuous filaments that are continuously elongated by a resin material, and a plurality of three-dimensionally irregular filaments are entangled irregularly, and their mutual contact portions are welded. And has elasticity.
次に、該立体網状構造体の従来の製造方法について説明する。
押出成形機のノズルに形成した多数の穴から前記の原料を、溶融状態で押し出して線条とし、これを下降させ、この線条を並設された一対の無端状のコンベア間に供給する。前記ノズルの穴は全て同径で、等間隔に配設されている。また、一対のコンベアは冷却水内に配設されている。
Next, a conventional method for producing the three-dimensional network structure will be described.
The raw material is extruded in a molten state from a large number of holes formed in the nozzles of the extrusion molding machine to form a line, which is lowered, and the line is supplied between a pair of endless conveyors arranged side by side. The nozzle holes are all the same diameter and are equally spaced. Moreover, a pair of conveyor is arrange | positioned in the cooling water.
これにより、押出成形機から押し出された溶融樹脂の線条は、コンベア間の水中において浮力などにより３次元方向に湾曲し、線条相互が部分的に接触して溶着し、その後、この溶着部が冷却水により冷却されて、その接触部が強固に結合されるとともに線条が固化して立体網状構造体が製造される。 Thereby, the filaments of the molten resin extruded from the extruder are curved in a three-dimensional direction by buoyancy or the like in the water between the conveyors, and the filaments are partially in contact with each other and welded. Is cooled by cooling water, the contact portions are firmly bonded, and the filaments are solidified to produce a three-dimensional network structure.
上記の方法により製造された立体網状構造体の内部の密度は均一で、その内部の硬さ（柔軟性）は一定である。 The internal density of the three-dimensional network structure manufactured by the above method is uniform, and the internal hardness (flexibility) is constant.
ところで、マットレスとしては、体圧分散性の良いものが望まれている。
また、マットレスは、そのマットレスをベッドの上に載せた状態で、マットレスの上に人が座り、人の足が地面につくことが望まれている。したがって、マットレスとしては、薄くて底付き感のないものが望まれている。
By the way, a mattress having good body pressure dispersibility is desired.
In addition, it is desired that a mattress sits on the mattress while the mattress is placed on a bed, and a person's feet are on the ground. Therefore, a mattress that is thin and has no bottoming is desired.
更に、マットレスは、その上に人が寝た時に、底づきしないことが望ましい。
前記立体網状構造体（クッション材）は、その厚みを厚くすれば、底づきすることを防止できるが、立体網状構造体を薄く形成した場合（例えば、１５ｃｍ以下）において、底づきを防止するには、立体網状構造体の弾力性を硬くする必要がある。しかし、このように硬くすると、体圧分散性能が悪くなるという問題点がある。
Furthermore, it is desirable that the mattress does not run out when a person sleeps on it.
The three-dimensional network structure (cushion material) can be prevented from bottoming out if the thickness is increased. However, when the three-dimensional network structure is formed thin (for example, 15 cm or less), it is possible to prevent bottoming out. It is necessary to make the elasticity of the three-dimensional network structure hard. However, there is a problem that the body pressure dispersion performance deteriorates when it is hardened in this way.
そこで、本発明は前記の問題点を解決した立体網状構造体及び立体網状構造体の製造方法を提供することを目的とするものである。 Then, this invention aims at providing the manufacturing method of the solid network structure which solved the said problem, and a solid network structure.
前記の課題を解決するために、請求項１記載の発明は、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体であって、
該立体網状構造体を、その使用時における表面側が柔らかく、その裏面側が硬くなるように、該立体網状構造体の硬さを変化させて形成したことを特徴とする立体網状構造体である。
In order to solve the above-mentioned problem, the invention according to claim 1 is a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The three-dimensional network structure is formed by changing the hardness of the three-dimensional network structure so that the front side is soft and the back side is hard when used.
請求項２記載の発明は、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体であって、
該立体網状構造体を、その使用時における表面側が柔らかく、その裏面側が硬くなるように、該立体網状構造体の硬さを変化させて、同時に一体成形したことを特徴とする立体網状構造体である。
The invention according to claim 2 is a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The three-dimensional network structure is characterized in that the three-dimensional network structure is integrally molded at the same time by changing the hardness of the three-dimensional network structure so that the front side is soft and the back side is hard when used. is there.
請求項３記載の発明は、請求項１又は２記載の立体網状構造体において、前記立体網状構造体を、前記表面側から前記裏面側に向って徐々に硬くなるようにしたことを特徴とするものである。 According to a third aspect of the present invention, in the three-dimensional network structure according to the first or second aspect, the three-dimensional network structure is gradually hardened from the front surface side toward the back surface side. Is.
請求項４記載の発明は、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体であって、
該立体網状構造体を、その表裏方向の一方の面側から他方の面側に向かって硬さを徐々に変化させて、同時に一体成形したことを特徴とする立体網状構造体である。
The invention according to claim 4 is a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The three-dimensional network structure is characterized in that the three-dimensional network structure is formed integrally at the same time by gradually changing the hardness from one surface side to the other surface side in the front and back direction.
また、請求項１乃至４のいずれかに記載の立体網状構造体において、前記立体網状構造体の前記表面側から裏面側への硬さの変化の度合いを、前記表面側ほど緩やかにしてもよい。 Further, in the three-dimensional network structure according to any one of claims 1 to 4, the degree of change in hardness from the front surface side to the back surface side of the three-dimensional network structure may be made gentler toward the front surface side. .
請求項５記載の発明は、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体であって、
該立体網状構造体を、その使用時における表面側に表層部を設け、該表層部の下部に主体部を設け、前記表層部と前記主体部を一体に形成し、
該主体部の前記表面側が柔らかく、前記裏面側が硬くなるように、該主体部の硬さを変化させて形成し、
前記表層部を、前記主体部の前記表面側よりも硬く形成したことを特徴とする立体網状構造体である。
The invention according to claim 5 is a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The three-dimensional network structure is provided with a surface layer portion on the surface side in use, a main body portion is provided below the surface layer portion, and the surface layer portion and the main body portion are integrally formed,
The main body is formed by changing the hardness of the main body so that the front side is soft and the back side is hard,
It is a three-dimensional network structure characterized in that the surface layer portion is formed harder than the surface side of the main body portion.
また、請求項５記載の立体網状構造体において、前記主体部を、前記表面側から前記裏面側に向って徐々に硬くなるようにしてもよい。 Further, in the three-dimensional network structure according to claim 5, the main body may be gradually hardened from the front surface side toward the back surface side.
また、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体であって、
前記立体網状構造体の使用時における表面側に人が寝た場合における、人の身長方向において、その人体の部位に応じて硬さを徐々に変化させて形成してもよい。
Also, a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
In the case where a person lies on the surface side when the three-dimensional network structure is used, it may be formed by gradually changing the hardness according to the part of the human body in the height direction of the person.
また、前記立体網状構造体の前記表面側に人が寝た場合における、その人の背骨を中心線とし、該中心線に近いほど前記立体網状構造体が軟らかく、該中心線と直交する方向の立体網状構造体の側部に向かうほど、前記立体網状構造体が硬くなるように、前記立体網状構造体の硬さを変化させてもよい。 In addition, when a person lies on the surface side of the three-dimensional network structure, the backbone of the person is the center line, and the closer to the center line, the softer the three-dimensional network structure is in a direction perpendicular to the center line. The hardness of the three-dimensional network structure may be changed so that the three-dimensional network structure becomes harder toward the side of the three-dimensional network structure.
また、前記線条の密度を変化させることにより、前記立体網状構造体の硬さを変化させてもよい。 Moreover, you may change the hardness of the said three-dimensional network structure by changing the density of the said filament.
また、前記線条の太さを変えることにより、前記立体網状構造体の硬さを変化させてもよい。 Moreover, you may change the hardness of the said solid network structure by changing the thickness of the said filament.
前記のような複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体であって、前記のような立体網状構造体を製造するために、例えば、前記の樹脂製の線条をノズルの複数の穴から押し出す押出成形機を有する立体網状構造体の製造装置において、前記ノズルにおける穴間の距離を、前記ノズルの一方の側部の中心と他方の側部の中心を結んだ線に近いほど広く、該線から該線に直交する方向の側部に向うほど狭くなるように、前記ノズルにおける穴間の距離を変えたことを特徴とする立体網状構造体の製造装置を用いることにより製造できる。 A three-dimensional network structure in which a plurality of resin filaments as described above are three-dimensionally irregularly entangled and partially fused. In the manufacturing apparatus of a three-dimensional network structure having an extrusion molding machine that extrudes the resin filaments from a plurality of holes in the nozzle, the distance between the holes in the nozzle is set to the center of one side of the nozzle and the other The distance between the holes in the nozzle is changed so that it is wider as it is closer to the line connecting the centers of the sides of the nozzle and narrower toward the side of the line in a direction perpendicular to the line. It can be manufactured by using a network structure manufacturing apparatus.
また、前記ノズルにおける穴径を、前記一方の側部の中心と他方の側部の中心を結んだ線に近いほど小さく、該線から該線に直交する方向の側部に向うほど大きくなるように、前記ノズルにおける穴径を変えた立体網状構造体の製造装置を用いても製造できる。 Further, the hole diameter in the nozzle is smaller as it is closer to the line connecting the center of the one side and the center of the other side, and is larger as it goes from the line to the side perpendicular to the line. In addition, it can be manufactured using a manufacturing apparatus of a three-dimensional network structure in which the hole diameter in the nozzle is changed.
また、前記線条を熱可塑性樹脂で形成してもよい。
請求項６記載の発明は、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体の製造方法であって、
ノズルに形成した複数の穴の間隔及び／又は穴径を、成形される立体網状構造体の使用時における表裏方向及び／又は該表裏方向と直交する方向に対応して変え、
前記ノズルの複数の穴から樹脂を押出して前記線条を形成し、前記立体網状構造体を、その表裏方向及び／又は該表裏方向と直交する方向の硬さを変化させて一体に形成することを特徴とする立体網状構造体の製造方法である。
Moreover, you may form the said filament with a thermoplastic resin.
The invention according to claim 6 is a method for manufacturing a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The interval between the plurality of holes formed in the nozzle and / or the hole diameter is changed in accordance with the front and back direction and / or the direction perpendicular to the front and back direction when using the molded three-dimensional network structure,
Resin is extruded from a plurality of holes of the nozzle to form the filament, and the three-dimensional network structure is integrally formed by changing the front and back direction and / or the hardness in the direction orthogonal to the front and back direction. This is a method for producing a three-dimensional network structure.
また、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体の製造方法であって、
ノズルに形成した複数の穴から樹脂を押出して前記線条を形成し、該線条を一対に配設したコンベア間に供給し、該コンベアの回転速度を徐々に変化させることにより、前記立体網状構造体の前記表面側に人が寝た場合における、人の身長方向において、その人体の部位に応じて硬さを徐々に変化させるようにしてもよい。
Further, a method for producing a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
Resin is extruded from a plurality of holes formed in the nozzle to form the filaments, the filaments are supplied between a pair of conveyors, and the rotational speed of the conveyors is gradually changed to form the three-dimensional network When a person lies on the surface side of the structure, the hardness may be gradually changed in the height direction of the person in accordance with the part of the human body.
また、前記線条を一対に配設したコンベア間に供給し、該コンベアの回転速度を徐々に変化させることにより、前記立体網状構造体の前記表面側に人が寝た場合における、人の身長方向において、その人体の部位に応じて硬さを徐々に変化させるようにしてもよい。 Further, the height of the person when the person sleeps on the surface side of the three-dimensional network structure by supplying the wire between a pair of conveyors and gradually changing the rotation speed of the conveyor. In the direction, the hardness may be gradually changed according to the part of the human body.
また、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体を製造するために、前記の樹脂製の線条をノズルの複数の穴から押し出す押出成形機を有する立体網状構造体の製造装置において、
前記ノズルにおける穴間の距離が、ノズルの一方の側部ほど広く、他方の側ほど狭くなるように、前記ノズルにおける穴間の距離を変えて前記ノズルの穴を形成したことを特徴とする立体網状構造体の製造装置を用いることにより請求項１乃至４記載の立体網状構造体を製造することができる。
Further, in order to manufacture a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused, the resin filaments are extruded from a plurality of nozzle holes. In the manufacturing apparatus of a three-dimensional network structure having an extruder,
The nozzle hole is formed by changing the distance between the holes in the nozzle so that the distance between the holes in the nozzle is wider toward one side of the nozzle and narrower toward the other side. The three-dimensional network structure according to any one of claims 1 to 4 can be manufactured by using a network-structure manufacturing apparatus.
また、複数の樹脂製の線条が立体的に不規則に絡まって部分的に融着された立体網状構造体を製造するために、前記の樹脂製の線条をノズルの複数の穴から押し出す押出成形機を有する立体網状構造体の製造装置において、
前記ノズルにおける穴径が、ノズルの一方の側部ほど小さく、他方の側ほど大きくなるように、前記ノズルにおける穴径を変えて前記ノズルの穴を形成したことを特徴とする立体網状構造体の製造装置を用いることにより請求項１乃至４記載の立体網状構造体を製造することができる。
Further, in order to manufacture a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused, the resin filaments are extruded from a plurality of nozzle holes. In the manufacturing apparatus of a three-dimensional network structure having an extruder,
A three-dimensional network structure, wherein the nozzle hole is formed by changing the hole diameter in the nozzle so that the hole diameter in the nozzle is smaller on one side of the nozzle and larger on the other side. The three-dimensional network structure according to claims 1 to 4 can be manufactured by using a manufacturing apparatus.
本発明の立体網状構造体は、連続した空隙を有し、かつ、この空隙率が大きいことから、従来からあるウレタンやエアーマットと比べて通気性が良く、体温の上昇を抑え、不必要な汗をかくことを防止できる。また、上記の構造を有することから軽い。上記の点で、本発明の立体網状構造体をマットレスに適用して特に有効であり、健常の人にも寝たきりの人にも適したマットレスを提供できる。 Since the three-dimensional network structure of the present invention has continuous voids and the void ratio is large, it has better air permeability than conventional urethane and air mats, suppresses an increase in body temperature, and is unnecessary. You can prevent sweating. Moreover, since it has said structure, it is light. In view of the above, the mattress of the present invention is particularly effective when applied to a mattress, and a mattress suitable for both healthy and bedridden people can be provided.
また、立体網状構造体は、空隙率が大きくかつ樹脂の線条で形成されるため、軽量で、かつ、洗浄や消毒が容易で、持ち運びや衛生的に良い。 Further, since the three-dimensional network structure has a large porosity and is formed of resin filaments, it is lightweight, easy to clean and disinfect, and is easy to carry and hygienically.
また、立体網状構造体を、その使用時における表面側ほど軟らかく、裏面側ほど硬くなるように立体網状構造体の硬さを変化させて形成したことで、立体網状構造体の厚みを薄くした場合であっても立体網状構造体の表面側に人が座ったり寝たりしたときに、体圧分散性が良く、かつ、底づきを防止できる。 Also, when the thickness of the three-dimensional network structure is reduced by forming the three-dimensional network structure by changing the hardness of the three-dimensional network structure so that it is softer on the front side and harder on the back side when used. Even so, when a person sits or sleeps on the surface side of the three-dimensional network structure, body pressure dispersibility is good, and bottoming out can be prevented.
また、仮に複数の立体網状構造体を積層することにより厚み方向の硬さを変化させたものと比較して、本願発明は１枚で形成できるために、生産効率が高い。また、従来の立体網状構造体よりも薄く形成できることから原材料が減少し、製造コストを低く抑えることができる。 Moreover, compared with what changed the hardness of the thickness direction by laminating | stacking a some three-dimensional network structure, since this invention can be formed by one sheet, production efficiency is high. In addition, since it can be formed thinner than a conventional three-dimensional network structure, raw materials are reduced, and manufacturing costs can be kept low.
請求項３記載の発明によれば、更に、表面側から裏面側に向かって徐々に立体網状構造体を硬く形成したことでより体圧分散性が向上する。 According to the invention described in claim 3, the body pressure dispersibility is further improved by gradually forming the three-dimensional network structure harder from the front surface side toward the back surface side.
請求項５記載の発明によれば、更に、主体部の上部より硬い表層部を設けたことにより、立体網状構造体の耐久性が増加する。 According to the fifth aspect of the present invention, the durability of the three-dimensional network structure is increased by providing the surface layer portion harder than the upper portion of the main portion.
請求項６記載の発明である製造方法を用いることにより、請求項１乃至５記載の立体網状構造体を製造することができる。 By using the manufacturing method according to the sixth aspect of the present invention, the three-dimensional network structure according to the first to fifth aspects can be manufactured.
本発明を実施するための最良の形態を図に示す実施例に基づいて説明する。 BEST MODE FOR CARRYING OUT THE INVENTION The best mode for carrying out the present invention will be described based on an embodiment shown in the drawings.
本発明の立体網状構造体１は、図１に示すように、直方体に形成され、その大きさ、厚みは任意に設定する。本実施例においては、マットレスとして使用できる任意の大きさ（面積）、厚みに設定するが、本実施例１においては厚みが１５ｃｍ以下に設定されている。 As shown in FIG. 1, the three-dimensional network structure 1 of the present invention is formed in a rectangular parallelepiped, and its size and thickness are arbitrarily set. In this embodiment, an arbitrary size (area) and thickness that can be used as a mattress are set, but in this embodiment, the thickness is set to 15 cm or less.
また、前記立体網状構造体１は、図２に示すように、樹脂、例えば熱可塑性樹脂からなる弾性又は伸縮性を有する材料により長尺に連続した連続線条３が多数本立体的に不規則に絡み合って、その相互の接触部４が溶着され、連続線条間に所定の空隙率の空隙５を有する構造体である。 Further, as shown in FIG. 2, the three-dimensional network structure 1 has a large number of continuous filaments 3 that are long and continuous with a material having elasticity or elasticity made of a resin, for example, a thermoplastic resin. In this structure, the mutual contact portions 4 are welded to each other, and a gap 5 having a predetermined porosity is provided between the continuous filaments.
また、その線条３の直径は所望に設定するが、本実施例においては１ｍｍ程度である。
前記弾性又は伸縮性を有する連続線条３の原料としては、ポリエチレン、ポリプロピレンなどのポリオレフィン、ポリエチレンテレフタレートなどのポリエステル、ナイロン６６などのポリアミド、ポリ塩化ビニル、ポリスチレン、こられの樹脂をベースとし共重合したコポリマやエラストマー、ＥＶＡ樹脂（エチレン酢酸ビニルコポリマー）、ＥＭＭＡ樹脂（エチレン・メチルメタクリレートコポリマー）、上記各種の樹脂を混合したものなどである。これらの原料のうち、好ましくはＥＶＡ樹脂や低密度ポリエチレンやポリエステルである。
Moreover, although the diameter of the filament 3 is set as desired, in this embodiment, it is about 1 mm.
The raw material of the continuous filament 3 having elasticity or stretchability includes polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides such as nylon 66, polyvinyl chloride, polystyrene, and copolymers based on these resins. Copolymers and elastomers, EVA resin (ethylene vinyl acetate copolymer), EMMA resin (ethylene methyl methacrylate copolymer), and a mixture of the above-mentioned various resins. Of these raw materials, EVA resin, low-density polyethylene and polyester are preferable.
ＥＶＡ樹脂は、伸縮性が大きいため後述する立体網状構造体１の体圧分散性をより向上できる。また、低密度ポリエチレンは、融点が高いために、立体網状構造体１の熱湯消毒や蒸気殺菌が可能となる。 Since EVA resin has a large stretchability, the body pressure dispersibility of the three-dimensional network structure 1 described later can be further improved. Moreover, since low-density polyethylene has a high melting point, hot water disinfection and steam sterilization of the three-dimensional network structure 1 are possible.
また、前記の線条３は、図３（ａ）に示すように無中空に形成した線条３や図３（ｂ）に示すように中空状にした線条３を用いても良い。図３（ｂ）に示すような中空状の線条３の方が、立体網状構造体１は軽くなり好ましい。 Moreover, the said filament 3 may use the filament 3 formed hollow as shown in Fig.3 (b), or the filament 3 formed hollow as shown in Fig.3 (b). The hollow filament 3 as shown in FIG. 3B is preferable because the three-dimensional network structure 1 becomes lighter.
立体網状構造体１は、図４の模式図（硬さを濃淡で表したもので、淡いほど軟らかく、濃いほど硬く表されている）に示すように、その一方の面である使用時における表面（以下、表面という）８側から他方の面である裏面９側に向かって、線条３の密度を徐々に高くすることにより、立体網状構造体１の表面８側から裏面９側に向かって徐々に（次第に）硬くなるように形成されている。つまり、立体網状構造体１は、その表面８側から裏面９側に向かって柔軟性が徐々に（段階的に）小さくなる一体多層構造、すなわち、複数のクッション材を積み重ねることなく一体の多層構造で形成されている。 As shown in the schematic diagram of FIG. 4 (the hardness is expressed in light and shade, the softer the light, the harder the darker), the three-dimensional network structure 1 is a surface at the time of use, as shown in FIG. By gradually increasing the density of the filaments 3 from the 8 side (hereinafter referred to as the front surface) toward the back surface 9 side, which is the other surface, the surface 8 side of the three-dimensional network structure 1 is directed toward the back surface 9 side. It is formed so as to be gradually (and gradually) harder. That is, the three-dimensional network structure 1 has an integrated multilayer structure in which flexibility gradually decreases in steps from the front surface 8 side to the rear surface 9 side, that is, an integrated multilayer structure without stacking a plurality of cushion materials. It is formed with.
立体網状構造体１は、前記のように樹脂製で弾性又は伸縮性を有する多数本の線条３が湾曲して部分的に結合されているため弾力性（クッション性）を有する。 The three-dimensional network structure 1 has elasticity (cushioning property) because a large number of the filaments 3 made of resin and having elasticity or stretchability are curved and partially joined as described above.
次に、前記立体網状構造体１の製造方法について述べる。
立体網状構造体１を製造するための、図５に示すような押出成形機１０の下部には、板状のノズル１１を有する。該ノズル１１には、図５に示すように、上下に貫通する多数の穴１２が設けられている。該穴１２の位置、大きさ、隣接する穴１２、１２間の距離は製造する立体網状構造体１に応じて任意に設定する。
Next, a method for manufacturing the three-dimensional network structure 1 will be described.
A plate-like nozzle 11 is provided at the lower part of the extruder 10 as shown in FIG. 5 for manufacturing the three-dimensional network structure 1. As shown in FIG. 5, the nozzle 11 is provided with a number of holes 12 penetrating vertically. The position and size of the holes 12 and the distance between the adjacent holes 12 and 12 are arbitrarily set according to the three-dimensional network structure 1 to be manufactured.
次に本実施例１におけるノズル１１について図５及び図６により説明する。図６は、ノズル１１の上面図である。 Next, the nozzle 11 in the first embodiment will be described with reference to FIGS. FIG. 6 is a top view of the nozzle 11.
ノズル１１の穴１２の径Ｌ３は全て１ｍｍである。
また、製造される立体網状構造体１の表裏方向（厚み方向）に対応するノズルの縦Ｘ方向の穴１２の列数は任意に設定されるが、本実施例１においては、図６に示すように１５列とし、その穴１２の列は等間隔で配設され、該列間の距離Ｌ１は任意に設定されるが、本実施例１においては８〜１５ｍｍに設定されている。
The diameter L3 of the hole 12 of the nozzle 11 is all 1 mm.
Moreover, although the number of rows of the holes 12 in the vertical X direction of the nozzle corresponding to the front and back direction (thickness direction) of the three-dimensional network structure 1 to be manufactured is arbitrarily set, in the first embodiment, as shown in FIG. Thus, the rows 12 are arranged at equal intervals, and the distance L1 between the rows is arbitrarily set, but in the first embodiment, it is set to 8 to 15 mm.
該縦Ｘ方向と直交する横方向Ｙの穴１２は、立体網状構造体１の表面８を形成する側Ａほど横方向Ｙの穴１２、１２間の距離Ｌ２を広く、立体網状構造体１の裏面９を形成する側Ｂほど狭く設定して形成されている。本実施例においては、横方向Ｙの穴１２、１２間の距離Ｌ２を、表面８を形成する側Ａから立体網状構造体１の裏面９を形成する側Ｂに向かって順に２２ｍｍ×２列、２０ｍｍ×２列、１８ｍｍ×２列、１６ｍｍ×２列、１４ｍｍ×２列、１２ｍｍ×３列、１０ｍｍ×２列とした。 The holes 12 in the horizontal direction Y orthogonal to the vertical X direction have a wider distance L2 between the holes 12 and 12 in the horizontal direction Y toward the side A that forms the surface 8 of the three-dimensional network structure 1. The side B on which the back surface 9 is formed is set narrower. In this example, the distance L2 between the holes 12 in the horizontal direction Y is set to 22 mm × 2 rows in order from the side A forming the front surface 8 toward the side B forming the back surface 9 of the three-dimensional network structure 1. 20 mm × 2 rows, 18 mm × 2 rows, 16 mm × 2 rows, 14 mm × 2 rows, 12 mm × 3 rows, 10 mm × 2 rows.
また、各列の穴１２は、その列に隣接する両側の列の穴１２と穴１２との間に位置するように設定されている。 The holes 12 in each row are set so as to be positioned between the holes 12 and 12 in the rows on both sides adjacent to the row.
前記ノズル１１に設けた多数の穴１２から前記の原料を、溶融状態で押し出して線条３とし、これを下降させ、この線条３を、図５に示すように、垂直方向に設置され、かつ、並設された一対の無端状のコンベア１３Ａ、１３Ｂ間に供給する。 The raw material is extruded in a molten state from a large number of holes 12 provided in the nozzle 11 to form a line 3, which is lowered, and the line 3 is installed in a vertical direction as shown in FIG. And it supplies between a pair of endless conveyors 13A and 13B arranged in parallel.
この一対のコンベア１３Ａ、１３Ｂの間隔は、押し出された溶融樹脂の線条３からなる集合群の幅と略同等か若干狭く設定されており、この一対のコンベア１３Ａ、１３Ｂは、前記線条３の下降速度よりも遅く回転するようになっている。また、一対のコンベア１３Ａ、１３Ｂは冷却水１４内に配設されている。 The interval between the pair of conveyors 13A and 13B is set to be substantially equal to or slightly narrower than the width of the aggregate group composed of the extruded molten resin filaments 3. It is designed to rotate slower than the descent speed. The pair of conveyors 13A and 13B is disposed in the cooling water 14.
これにより、押出成形機１０から押し出された（吐出された）溶融樹脂の線条３は、コンベア１３Ａ、１３Ｂ間の冷却水１４中において浮力などにより３次元方向に湾曲し、図２に示すように、線条相互が部分的に接触して溶着し、その後、この溶着部が冷却水１４により冷却されて、その接触部４が強固に結合されるとともに線条３が固化する。 Thereby, the filament 3 of the molten resin extruded (discharged) from the extruder 10 is curved in a three-dimensional direction due to buoyancy in the cooling water 14 between the conveyors 13A and 13B, as shown in FIG. In addition, the filaments are in partial contact with each other and welded. Then, the welded portion is cooled by the cooling water 14, and the contact portion 4 is firmly bonded and the filament 3 is solidified.
そして、コンベア１３Ａ、１３Ｂから流れ出ることにより、所定の厚みの平板状の立体網状構造体１が得られ、これを必要な寸法に切断する。 Then, by flowing out from the conveyors 13A and 13B, a flat three-dimensional network structure 1 having a predetermined thickness is obtained and cut into necessary dimensions.
上記製法により、立体網状構造体１は、その表面８側から裏面９側に向かって、線条３の密度が徐々に高い、すなわち、徐々に硬い一体構造に形成される。 By the above manufacturing method, the three-dimensional network structure 1 is formed into a monolithic structure in which the density of the filaments 3 is gradually increased from the front surface 8 side toward the back surface 9 side, that is, gradually.
なお、前記穴１２の位置、穴１２の径Ｌ３、穴１２、１２間の距離Ｌ２、ノズル１１からの樹脂の供給速度や一対のコンベア１３Ａと１３Ｂの間の間隔、コンベア１３Ａ、１３Ｂの速度などを所望に設定することにより、空隙率、すなわち線条３の密度を所望に設定することができ、この密度を所望に設定することにより、所望の弾性係数の立体網状構造体１が得られる。 The position of the hole 12, the diameter L3 of the hole 12, the distance L2 between the holes 12 and 12, the supply speed of the resin from the nozzle 11, the interval between the pair of conveyors 13A and 13B, the speed of the conveyors 13A and 13B, etc. Can be set as desired, and the density of the filament 3 can be set as desired. By setting this density as desired, the three-dimensional network structure 1 having a desired elastic modulus can be obtained.
また、立体網状構造体１の空隙率については所望に設定するが、７０〜９８％の範囲がよく、より好ましくは８５〜９８％がよい。 The porosity of the three-dimensional network structure 1 is set as desired, but it is preferably in the range of 70 to 98%, more preferably 85 to 98%.
次に、本発明の立体網状構造体１の効果について説明する。
立体網状構造体１は、樹脂からなる立体網状構造体１のみから構成され、かつ、軽量であるため、水洗い等による洗浄が容易で、かつ、水洗い後に立体網状構造体１を振るのみで水切りが行える。また、水切りをしなくても洗浄後の乾燥性も極めてよいため、衛生面に優れている。
Next, the effect of the three-dimensional network structure 1 of the present invention will be described.
The three-dimensional network structure 1 is composed only of the three-dimensional network structure 1 made of resin and is lightweight, so that it can be easily washed with water and the like, and can be drained by simply shaking the three-dimensional network structure 1 after washing. Yes. Moreover, since the drying property after washing | cleaning is very good even if it does not drain, it is excellent in the sanitary surface.
また、乾燥性が良いため、アルコールや安定化二酸化塩素による消毒も容易に行える。また、線条３を低密度ポリエチレン等の融点の高い樹脂で作成した場合には、熱湯消毒や蒸気殺菌を実施でき衛生面に優れている。 In addition, since it has good drying properties, it can be easily disinfected with alcohol or stabilized chlorine dioxide. Moreover, when the filament 3 is made of a resin having a high melting point such as low density polyethylene, hot water disinfection and steam sterilization can be performed, which is excellent in terms of hygiene.
また、立体網状構造体１は、樹脂のみからなるためリサイクルも容易である。
そのため、立体網状構造体１をマットレスとして使用する場合には、立体網状構造体１の表面に薄い表皮を設け、更に、カバー等により全体を***するだけでよい。表皮は薄くて良い為、立体網状構造体１に加えられた荷重を、弾性又は伸縮性を有するそれぞれの線条３が受け止めることができ体圧分散性に優れる。なお、表皮は設けず、カバーにより全体を***するだけでもよい。
Moreover, since the three-dimensional network structure 1 consists only of resin, it is easy to recycle.
Therefore, when the three-dimensional network structure 1 is used as a mattress, it is only necessary to provide a thin skin on the surface of the three-dimensional network structure 1 and further cover the whole with a cover or the like. Since the skin may be thin, the load applied to the three-dimensional network structure 1 can be received by each of the filaments 3 having elasticity or stretchability, and the body pressure dispersibility is excellent. It should be noted that the entire skin may be covered with a cover without providing a skin.
また、立体網状構造体１は、線条３が絡み合って、連続した空隙５を有し、かつ、その空隙率が大きいため、通気性が良く、更に前記のように表皮やカバーを通気性が良く薄い材料で形成できることから、通気性が良く、かつ、軽く容易に移動することができる。また、うつ伏せに寝た場合でも、通気性が良いために安全である。 In addition, the three-dimensional network structure 1 has continuous air gaps 5 in which the filaments 3 are intertwined with each other, and has a large porosity, so that the air permeability is good. Since it can be formed of a good and thin material, it has good air permeability and can be moved lightly and easily. Even when lying on its face, it is safe because of its good breathability.
また、寝たきりの人において、寝返りができない人や寝返りができる人に合わせた硬さや優れた体圧分散性を容易に設定できるため褥瘡対策としても効果がある。 In addition, in a bedridden person, hardness and excellent body pressure dispersibility suitable for those who cannot turn over or who can turn over can be easily set, and this is also effective as a measure against pressure ulcers.
また、立体網状構造体１の表面８側から裏面９側に向かって、線条３の密度が徐々に高くなるように形成したことで、立体網状構造体１の表面８側から裏面９側に向かうほど段階的に（徐々に）硬くなる。これにより、立体網状構造体１を、１５ｃｍ以下の厚みに形成した場合においても、その表面８側に人が座ったり、寝たりした時に、体圧分散性が良く、かつ、底づきを防止することができる。 In addition, the density of the filaments 3 is gradually increased from the front surface 8 side to the back surface 9 side of the three-dimensional network structure 1, so that the three-dimensional network structure 1 has a surface 8 side to a back surface 9 side. The more you head, the harder you are. Thereby, even when the three-dimensional network structure 1 is formed with a thickness of 15 cm or less, when a person sits on the surface 8 side or sleeps, the body pressure dispersibility is good and the bottom is prevented. be able to.
また、一体に形成された１枚の立体網状構造体の内部の硬さを変化させることで、底づきを防止することができる。また、仮に複数の立体網状構造体を積層することにより厚み方向の硬さを変化させたものと比較して、本願発明は１枚で形成できるために、生産効率が高い。また、前記従来の立体網状構造体と比較して、薄く形成できることから原材料が減少し、製造コストを低く抑えることができる。 In addition, bottoming out can be prevented by changing the internal hardness of one integrally formed three-dimensional network structure. Moreover, compared with what changed the hardness of the thickness direction by laminating | stacking a some three-dimensional network structure, since this invention can be formed by one sheet, production efficiency is high. Moreover, since it can form thinly compared with the said conventional three-dimensional network structure, a raw material reduces and manufacturing cost can be held down low.
図７は実施例２を示す。
本実施例２は、前記実施例１のノズル１１の変形例である。
FIG. 7 shows a second embodiment.
The second embodiment is a modification of the nozzle 11 of the first embodiment.
本実施例２のノズル２１は、前記実施例１のノズル１１と同様に、立体網状構造体１の表裏方向（厚み方向）に対応するノズル２１の縦Ｘ方向には、図７に示すように、１５列の穴２２が等間隔に配設され、該列間Ｌ１の距離は８〜１５ｍｍに設定されている。また、ノズル２１の穴２２の径Ｌ３は全て１ｍｍである。 The nozzle 21 of the second embodiment is similar to the nozzle 11 of the first embodiment in the vertical X direction of the nozzle 21 corresponding to the front and back direction (thickness direction) of the three-dimensional network structure 1 as shown in FIG. , 15 rows of holes 22 are arranged at equal intervals, and the distance between the rows L1 is set to 8 to 15 mm. The diameter L3 of the hole 22 of the nozzle 21 is all 1 mm.
また、該縦Ｘ方向と直交する横方向Ｙの穴２２、２２間の距離Ｌ２を、表面８を形成する側Ａから立体網状構造体１の裏面９を形成する側Ｂに向かって順に２０ｍｍ×６列、１７ｍｍ×５列、１４ｍｍ×３列、１０ｍｍ×１列としたものである。 Further, the distance L2 between the holes 22 in the lateral direction Y perpendicular to the longitudinal X direction is set to 20 mm × in order from the side A forming the front surface 8 toward the side B forming the back surface 9 of the three-dimensional network structure 1. 6 rows, 17 mm × 5 rows, 14 mm × 3 rows, 10 mm × 1 row.
上記のようにノズル間隔を設定したことで、立体網状構造体１の硬さの変化の度合いが、表面８側ほど緩やかで、裏面９側ほど急に形成される。つまり、立体網状構造体１の表面８から裏面９までの硬さは、放物線に近似したものとなる。 By setting the nozzle interval as described above, the degree of change in the hardness of the three-dimensional network structure 1 is more gradual toward the front surface 8 side and abruptly formed toward the back surface 9 side. That is, the hardness from the front surface 8 to the back surface 9 of the three-dimensional network structure 1 is approximate to a parabola.
その他の部材、製造方法は前記実施例１と同様であるので、その説明を省略する。
また、前記実施例１と同様の作用、効果を奏する。
Since other members and the manufacturing method are the same as those in the first embodiment, description thereof is omitted.
In addition, the same operations and effects as the first embodiment are achieved.
本実施例２においては、更に、立体網状構造体１の硬さの変化の度合いを、表面８側ほど緩やかに形成したことで、立体網状構造体１の表面側に人が寝た場合に、その人体に近いほど軟らかいために、寝心地がよい。また、裏面９に向かうほど硬さの変化の度合いを高くすることで底づき感が減少する。つまり、体圧分散性を向上させ、かつ、底づきを防止できる。 In the second embodiment, the degree of change in the hardness of the three-dimensional network structure 1 is more gradually formed toward the surface 8 side, so that when a person lies on the surface side of the three-dimensional network structure 1, The closer to the human body, the softer it is, the better it is to sleep. In addition, the feeling of bottoming is reduced by increasing the degree of change in hardness toward the back surface 9. That is, body pressure dispersibility can be improved and bottoming out can be prevented.
図８は実施例３を示す。
本実施例３は、前記実施例１、２のノズル１１、２１の変形例である。
FIG. 8 shows a third embodiment.
The third embodiment is a modification of the nozzles 11 and 21 of the first and second embodiments.
本実施例３のノズル３１は、前記実施例１、２のノズル１１、２１と同様に、立体網状構造体１の表裏方向（厚み方向）に対応するノズルの縦Ｘ方向には、図８に示すように、１５列の穴３２が等間隔に配設され、該列間の距離Ｌ１は８〜１５ｍｍに設定されている。また、ノズル３１の穴３２の径Ｌ３は全て１ｍｍである。 The nozzle 31 of the third embodiment is similar to the nozzles 11 and 21 of the first and second embodiments in the vertical X direction of the nozzle corresponding to the front and back direction (thickness direction) of the three-dimensional network structure 1 as shown in FIG. As shown, 15 rows of holes 32 are arranged at equal intervals, and the distance L1 between the rows is set to 8 to 15 mm. Further, the diameter L3 of the hole 32 of the nozzle 31 is all 1 mm.
また、該縦Ｘ方向に直交する横方向Ｙの穴３２、３２間の距離Ｌ２を、表面８を形成する側Ａから立体網状構造体１の裏面９を形成する側Ｂに向かって順に２２ｍｍ×１０列、１８ｍｍ×５列としたものである。 Further, the distance L2 between the holes 32 in the horizontal direction Y orthogonal to the vertical X direction is set to 22 mm × in order from the side A forming the front surface 8 toward the side B forming the back surface 9 of the three-dimensional network structure 1. 10 rows, 18 mm × 5 rows.
その他の部材、製造方法は前記実施例１、２と同様であるので、その説明を省略する。
また、前記実施例１、２と同様の作用、効果を奏する。
Since other members and the manufacturing method are the same as those in the first and second embodiments, description thereof will be omitted.
In addition, the same operations and effects as the first and second embodiments are achieved.
本実施例４は、前記実施例１、２のノズル１１、２１の変形例である。
本実施例４のノズルは、前記実施例１乃至３のノズル１１、２１、３１と同様に、立体網状構造体１の表裏方向（厚み方向）に対応するノズルの縦Ｘ方向には、１５列の穴が等間隔に配設され、該列間の距離Ｌ１は８〜１５ｍｍに設定されている。また、ノズルの穴の径Ｌ３は全て１ｍｍである。
The fourth embodiment is a modification of the nozzles 11 and 21 of the first and second embodiments.
As with the nozzles 11, 21, and 31 of Examples 1 to 3, the nozzles of Example 4 have 15 rows in the vertical X direction of the nozzles corresponding to the front and back direction (thickness direction) of the three-dimensional network structure 1. Are arranged at equal intervals, and the distance L1 between the rows is set to 8 to 15 mm. The diameters L3 of the nozzle holes are all 1 mm.
また、該縦Ｘ方向に直交する横方向Ｙの穴間の距離Ｌ２を、表面８を形成する側Ａから立体網状構造体１の裏面９を形成する側Ｂに向かって連続的に（徐々に）狭くなるように、横方向Ｙの穴間の距離Ｌ２を変えたものである。つまり、横方向Ｙの穴間の距離Ｌ２を１５列全てに亘って変えたものである。 Further, the distance L2 between the holes in the horizontal direction Y orthogonal to the vertical X direction is continuously (gradually) from the side A forming the front surface 8 toward the side B forming the back surface 9 of the three-dimensional network structure 1. ) The distance L2 between the holes in the lateral direction Y is changed so as to be narrower. That is, the distance L2 between the holes in the horizontal direction Y is changed over all 15 rows.
その他の部材、製造方法は前記実施例１乃至３と同様であるので、その説明を省略する。 Since other members and the manufacturing method are the same as those in the first to third embodiments, description thereof will be omitted.
また、前記実施例１乃至３と同様の作用、効果を奏する。 In addition, the same operations and effects as the first to third embodiments are obtained.
図９は実施例５を示す。
前記実施例１乃至４においては、ノズル１１、２１、３１の穴１２、２２、３２の径を全て１ｍｍとしたが、本実施例５におけるノズル４１は、図９に示すように、横方向Ｙの穴４２は全て同じ穴径とし、該横Ｙ方向と直交する縦方向Ｘの穴４２の穴径を、立体網状構造体１の表面８を形成する側Ａほど小さく、立体網状構造体１の裏面９を形成する側Ｂほど大きく設定されている。なお、図９は、本実施例５を示す模式図であり、ノズル４１のＸ方向の穴４２の列数、列間の距離Ｌ１、横Ｙ方向の穴４２の数、穴４２、４２間の距離Ｌ２は任意に設定する。
FIG. 9 shows a fifth embodiment.
In the first to fourth embodiments, the diameters of the holes 12, 22, and 32 of the nozzles 11, 21, and 31 are all set to 1 mm. However, as shown in FIG. The holes 42 have the same hole diameter, and the hole diameter in the vertical direction X perpendicular to the transverse Y direction is smaller on the side A that forms the surface 8 of the three-dimensional network structure 1. The side B on which the back surface 9 is formed is set larger. FIG. 9 is a schematic diagram showing the fifth embodiment. The number of rows of the holes 42 in the X direction of the nozzle 41, the distance L1 between the rows, the number of the holes 42 in the horizontal Y direction, and the space between the holes 42, 42. The distance L2 is set arbitrarily.
なお、Ｘ方向の穴４２の列間の距離Ｌ１を全て同じに設定しても良いし、前記実施例１乃至４のように縦方向Ｘにしたがって変えても良い。 The distances L1 between the rows of the holes 42 in the X direction may all be set to be the same, or may be changed according to the vertical direction X as in the first to fourth embodiments.
その他の部材、製造方法は前記実施例１乃至４と同様であるので、その説明を省略する。 Since other members and the manufacturing method are the same as those in the first to fourth embodiments, the description thereof is omitted.
上記のようにノズル４１の穴４２の径を設定することにより、立体網状構造体１の表面８側から裏面９側に向かって線条３の径が太くなり、これにより、立体網状構造体１の表面８から裏面９側に向って、立体網状構造体１を徐々に（次第に）硬くすることが出来、前記実施例１乃至４と同様の作用、効果を奏する。 By setting the diameter of the hole 42 of the nozzle 41 as described above, the diameter of the filament 3 increases from the front surface 8 side to the back surface 9 side of the three-dimensional network structure 1, and thereby the three-dimensional network structure 1. From the front surface 8 to the back surface 9 side, the three-dimensional network structure 1 can be gradually and gradually hardened, and the same operations and effects as in the first to fourth embodiments are achieved.
図１０は実施例６を示す。
前記実施例１乃至５においては、立体網状構造体１の表面８側から裏面９側に向かって、線条３の密度を徐々に高く形成したが、本実施例６においては、立体網状構造体５０の表面８側に表層部５１を設け、該表層部５１の下部に主体部５２を設け、該表層部５１と主体部５２を一体に形成し、該主体部５２の表面８側より裏面９側に向かって、線条３の密度を徐々に（次第に）高く形成したものである。また、前記表層部５１の線条３の密度は、主体部５２の表面８側付近における線条３の密度よりも高く形成されている。つまり、表層部５１は、主体部５２の表面８側付近よりも硬く形成されている。
FIG. 10 shows a sixth embodiment.
In Examples 1 to 5, the density of the filaments 3 was gradually increased from the front surface 8 side to the back surface 9 side of the three-dimensional network structure 1, but in the sixth example, the three-dimensional network structure was formed. 50, a surface layer portion 51 is provided on the front surface 8 side, a main body portion 52 is provided below the surface layer portion 51, the surface layer portion 51 and the main body portion 52 are integrally formed, and a back surface 9 is formed from the front surface 8 side of the main body portion 52. The density of the filament 3 is gradually increased toward the side. Further, the density of the filament 3 in the surface layer portion 51 is formed higher than the density of the filament 3 in the vicinity of the surface 8 side of the main body portion 52. That is, the surface layer portion 51 is formed to be harder than the vicinity of the surface 8 side of the main body portion 52.
前記表層部５１の厚み、硬さは、任意に設定する。
次に、本実施例６の立体網状構造体５０の製造方法について説明する。
The thickness and hardness of the surface layer portion 51 are arbitrarily set.
Next, a method for manufacturing the three-dimensional network structure 50 according to the sixth embodiment will be described.
本実施例５の立体網状構造体５０の製造方法は、前記実施例と同様に前記ノズル１１、２１、３１、４１に設けた多数の穴１２、２２、３２、４２から前記の原料を、溶融状態で押し出して線条３とし、これを下降させ、この線条３を、垂直方向に設置し、かつ、並設された一対の無端状のコンベア１３Ａ、１３Ｂ間に供給する。該無端状のコンベア１３Ａ、１３Ｂの間隔を、押し出された溶融樹脂の線条３からなる集合群の幅より短く設定し、図１０に示すように、板５５等により押し出された溶融樹脂の線条３のうち側部に位置する線条３Ａを、内側に移動させることにより、立体網状構造体５０の表面８及び裏面９における線条３の密度が高くなり、表層部５１が形成される。 In the manufacturing method of the three-dimensional network structure 50 according to the fifth embodiment, the raw material is melted from a large number of holes 12, 22, 32, and 42 provided in the nozzles 11, 21, 31, and 41 in the same manner as the previous embodiment. The strip 3 is extruded in a state to be lowered, and the strip 3 is lowered, and is supplied between a pair of endless conveyors 13A and 13B arranged in the vertical direction and arranged side by side. The interval between the endless conveyors 13A and 13B is set to be shorter than the width of the aggregate group composed of the extruded molten resin filaments 3, and as shown in FIG. 10, the molten resin line extruded by the plate 55 or the like. By moving the line 3 </ b> A located on the side of the line 3 to the inside, the density of the line 3 on the front surface 8 and the back surface 9 of the three-dimensional network structure 50 is increased, and the surface layer part 51 is formed.
無端状のコンベア１３Ａ、１３Ｂの間隔を調節することにより、表層部５１の厚みを調節することができる。 The thickness of the surface layer portion 51 can be adjusted by adjusting the interval between the endless conveyors 13A and 13B.
その他の部材、製造方法は前記実施例１乃至５と同様であるので、その説明を省略する。 Since other members and the manufacturing method are the same as those in the first to fifth embodiments, the description thereof is omitted.
本実施例６においても前記実施例１乃至５と同様の作用、効果を奏する。
また、本実施例６においては、表層部５１を設けたことにより、立体網状構造体５０の耐久性が増加する。
In the sixth embodiment, the same operations and effects as the first to fifth embodiments are achieved.
In the sixth embodiment, the provision of the surface layer portion 51 increases the durability of the three-dimensional network structure 50.
図１１は実施例７を示す。
前記実施例１乃至６においては、立体網状構造体１の厚み方向（表面８から裏面９方向）αのみ立体網状構造体１の硬さを変化させたが、本実施例７は、立体網状構造体６０の厚み方向α及び縦方向β（図１１の模式図に示すように、人６５が上部に寝た場合における人体の身長方向）の硬さを徐々に変化させたものである。なお、図１１は、模式図で硬さを濃淡で表し、淡いほど軟らかく、濃いほど硬く表されている。また、図１１は、立体網状構造体６０の縦方向βの変化を見やすくするために、立体網状構造体６０の厚み方向αへの硬さの変化については図示していない。また、立体網状構造体６０を表面８側からみた場合、縦方向βについては硬さを変化させるが、人体６５から側方向への硬さについては略同じになるように形成されている。
FIG. 11 shows a seventh embodiment.
In Examples 1 to 6, the hardness of the three-dimensional network structure 1 was changed only in the thickness direction (from the front surface 8 to the back surface 9) α of the three-dimensional network structure 1, but in the seventh example, the three-dimensional network structure The hardness of the body 60 in the thickness direction α and the longitudinal direction β (the height direction of the human body when the person 65 lies down as shown in the schematic diagram of FIG. 11) is gradually changed. In addition, FIG. 11 is a schematic diagram showing the hardness in light and shade, where the lighter is softer and the darker is harder. Further, FIG. 11 does not show the change in the hardness of the three-dimensional network structure 60 in the thickness direction α in order to make the change in the vertical direction β of the three-dimensional network structure 60 easier to see. Further, when the three-dimensional network structure 60 is viewed from the surface 8 side, the hardness is changed in the longitudinal direction β, but the hardness in the lateral direction from the human body 65 is substantially the same.
立体網状構造体６０の厚み方向αの硬さの変化は前記実施例１乃至６と同様に形成されている。 The change in the hardness in the thickness direction α of the three-dimensional network structure 60 is formed in the same manner as in the first to sixth embodiments.
また、立体網状構造体６０は、図１１に示すように、人６５が寝た場合における、人体６５の頭部、肩胛骨、臀部、踵部が位置する部位を横方向全体に亘って軟らかく形成し、該部位から身長方向に向かうほど徐々に硬く形成されている。 In addition, as shown in FIG. 11, the three-dimensional network structure 60 softly forms a portion where the head, shoulder ribs, buttocks, and buttocks of the human body 65 are located in the horizontal direction when the person 65 is sleeping. It is gradually formed so hard that it goes to the height direction from this part.
その他の部材等は前記実施例１乃至６と同様であるので、その説明を省略する。
次に、本実施例７の立体網状構造体６０の製造方法について説明する。
Since other members are the same as those in the first to sixth embodiments, the description thereof is omitted.
Next, a method for manufacturing the three-dimensional network structure 60 of Example 7 will be described.
立体網状構造体６０を製造するための、押出成形機１０及び、そのノズル１１、２１、３１、４１については、前記実施例１乃至６と同様のものを使用する。 As for the extruder 10 and its nozzles 11, 21, 31, 41 for producing the three-dimensional network structure 60, the same ones as in the first to sixth embodiments are used.
前記ノズル１１、２１、３１、４１に設けた多数の穴１２、２２、３２、４２から前記実施例と同様の原料を、溶融状態で押し出して線条３とし、これを下降させ、この線条３を、前記実施例と同様の一対の無端状のコンベア１３Ａ、１３Ｂ間に供給する。 The same raw material as in the above embodiment is extruded in a molten state from a large number of holes 12, 22, 32, and 42 provided in the nozzles 11, 21, 31, and 41 to form a line 3, and this is lowered. 3 is supplied between a pair of endless conveyors 13A and 13B similar to the above embodiment.
このコンベア１３Ａ、１３Ｂの回転速度を徐々に速めると、線条３の密度は徐々に疎となりその部位における立体網状構造体６０は徐々に軟らかく形成される。一方、コンベア１３Ａ、１３Ｂの回転速度を徐々に遅くすると、線条３の密度は徐々に密となりその部位における立体網状構造体６０は徐々に硬く形成される。このように、コンベア１３Ａ、１３Ｂの回転速度を緩やかに変化させることにより、上記のように人体６５の部位に応じて立体網状構造体６０の縦方向βの硬さを徐々に変化させることが出来る。 When the rotational speeds of the conveyors 13A and 13B are gradually increased, the density of the filament 3 gradually becomes sparse, and the three-dimensional network structure 60 at the portion is gradually softened. On the other hand, when the rotational speed of the conveyors 13A and 13B is gradually decreased, the density of the filaments 3 is gradually increased, and the three-dimensional network structure 60 at the portion is gradually formed to be hard. Thus, by gradually changing the rotation speed of the conveyors 13A and 13B, the hardness in the longitudinal direction β of the three-dimensional network structure 60 can be gradually changed according to the portion of the human body 65 as described above. .
その他の製造方法は前記１乃至６と同様であるので、その説明を省略する。
また、本実施例７においても前記実施例１乃至６と同様の作用、効果を奏する。
Since other manufacturing methods are the same as those in 1 to 6, description thereof will be omitted.
Also in the seventh embodiment, the same operations and effects as the first to sixth embodiments are achieved.
また、本実施例７においては、立体網状構造体６０の厚み方向α及び人体６５の部位に応じて立体網状構造体６０の縦方向βの硬さを徐々に変化させた、つまり、立体網状構造体６０の二方向について硬さを変化させたことにより、より立体網状構造体６０の体圧分散性が向上する。 In the seventh embodiment, the hardness in the longitudinal direction β of the three-dimensional network structure 60 is gradually changed according to the thickness direction α of the three-dimensional network structure 60 and the part of the human body 65, that is, the three-dimensional network structure. By changing the hardness in two directions of the body 60, the body pressure dispersibility of the three-dimensional network structure 60 is further improved.
なお、本実施例７においては、立体網状構造体６０の厚み方向α及び人体６５の部位に応じて立体網状構造体６０の縦方向βの硬さを徐々に変化させたが、立体網状構造体６０の厚み方向αの硬さを変化させず、人体６５の部位に応じて立体網状構造体６０の縦方向βの硬さのみを徐々に変化させてもよい。 In Example 7, although the hardness in the longitudinal direction β of the three-dimensional network structure 60 was gradually changed according to the thickness direction α of the three-dimensional network structure 60 and the part of the human body 65, the three-dimensional network structure Instead of changing the hardness in the thickness direction α of 60, only the hardness in the vertical direction β of the three-dimensional network structure 60 may be gradually changed according to the part of the human body 65.
図１２、図１３は実施例８を示す。
前記実施例６においては、立体網状構造体６０の厚み方向α及び縦方向β（図１１に示すように、人６５が立体網状構造体６０の上部に寝た場合における人体６５の身長方向）の硬さを変化させたものであるが、本実施例８においては、厚み方向α及び縦方向β及び図１２の模式図に示すように、横方向γ（人体７５の身長方向に直交する方向）の三方向において立体網状構造体７０の硬さを変化させたものである。なお、図１２は、模式図で硬さを濃淡で表し、淡いほど軟らかく、濃いほど硬く表されている。また、図１２は、立体網状構造体７０の横方向γの変化を見やすくするために、立体網状構造体７０の縦方向βの硬さの変化については図示していない。
12 and 13 show an eighth embodiment.
In the sixth embodiment, the thickness direction α and the vertical direction β of the three-dimensional network structure 60 (the height direction of the human body 65 when the person 65 lies on the top of the three-dimensional network structure 60 as shown in FIG. 11). Although the hardness is changed, in the eighth embodiment, as shown in the thickness direction α and the vertical direction β and the schematic diagram of FIG. 12, the horizontal direction γ (the direction orthogonal to the height direction of the human body 75). The hardness of the three-dimensional network structure 70 is changed in the three directions. In addition, FIG. 12 is a schematic diagram showing the hardness in light and shade, where the lighter is softer and the darker is harder. Further, FIG. 12 does not show the change in the hardness in the vertical direction β of the three-dimensional network structure 70 in order to make the change in the horizontal direction γ of the three-dimensional network structure 70 easier to see.
立体網状構造体７０の厚み方向αの硬さの変化は前記実施例１乃至６と同様に形成されている。また、立体網状構造体７０の縦方向βの硬さの変化は前記実施例７と同様に形成されている。 The change in the hardness in the thickness direction α of the three-dimensional network structure 70 is formed in the same manner as in the first to sixth embodiments. Further, the change in the hardness in the longitudinal direction β of the three-dimensional network structure 70 is formed in the same manner as in the seventh embodiment.
また、立体網状構造体７０は、図１２に示すように、人７５が寝た場合における、その人７５の背骨を中心線７０ａとし、該中心線と直交する方向γの立体網状構造体７０の側部７０ｂに向かうほど、前記立体網状構造体７０を徐々に（次第に）硬く形成している。 In addition, as shown in FIG. 12, the three-dimensional network structure 70 has a three-dimensional network structure 70 in a direction γ perpendicular to the center line, with the spine of the person 75 as the center line 70 a when the person 75 is sleeping. The three-dimensional network structure 70 is gradually and gradually formed harder toward the side part 70b.
その他の部材等は前記実施例１乃至７と同様であるので、その説明を省略する。
次に、本実施例８の立体網状構造体７０の製造方法について説明する。
Other members and the like are the same as those in the first to seventh embodiments, and the description thereof is omitted.
Next, a method for manufacturing the three-dimensional network structure 70 of Example 8 will be described.
立体網状構造体７０を製造するための、押出成形機１０に設けられるノズル７１は図１３に示すものを用いる。該ノズル７１には複数の穴７２が設けられている。該穴７２は、図１３に示すように、立体網状構造体７０の表裏方向（厚み方向）αに対応するノズルの縦Ｘ方向には穴７２の列間が等間隔に配設され、かつ、立体網状構造体７０の表面８を形成する側Ａほど横方向Ｙの穴７２の穴径を小さくし、立体網状構造体７０の裏面９を形成する側Ｂほど穴７２の穴径が大きく設定され、かつ、横方向Ｙにおける中心線Ｃ−Ｃから横方向Ｙの側部Ｄ、Ｅに向かって、穴径が徐々に大きく設定されている。 The nozzle 71 provided in the extruder 10 for producing the three-dimensional network structure 70 is the one shown in FIG. The nozzle 71 is provided with a plurality of holes 72. As shown in FIG. 13, the holes 72 are arranged at equal intervals between the rows of holes 72 in the longitudinal X direction of the nozzle corresponding to the front and back direction (thickness direction) α of the three-dimensional network structure 70, and The hole diameter of the hole 72 in the lateral direction Y is made smaller toward the side A forming the surface 8 of the three-dimensional network structure 70, and the hole diameter of the hole 72 is set larger as the side B forming the back surface 9 of the three-dimensional network structure 70. In addition, the hole diameter is gradually increased from the center line C-C in the lateral direction Y toward the side portions D and E in the lateral direction Y.
なお、図１３は、本実施例７を示す模式図であり、ノズル７１のＸ方向の穴７２の列数、列間の距離Ｌ１、横方向Ｙの穴７２の数、穴７２、７２間の距離Ｌ２は任意に設定する。 FIG. 13 is a schematic diagram illustrating the seventh embodiment. The number of rows of the holes 72 in the X direction of the nozzle 71, the distance L1 between the rows, the number of the holes 72 in the lateral direction Y, and between the holes 72 and 72 are illustrated. The distance L2 is set arbitrarily.
前記ノズル７１を使用することにより、径が大きい穴７２から押出された線条３は太く、径が小さい穴７２から押出された線条３は細くなり、立体網状構造体７０の三方向の硬さを変化させることができる。 By using the nozzle 71, the filament 3 extruded from the hole 72 having a large diameter is thick, the filament 3 extruded from the hole 72 having a small diameter is thin, and the three-dimensional network structure 70 is hardened in three directions. It can be changed.
なお、前記のようにノズル７１の穴７２の穴径Ｌ３を変化させるのではなく、穴７２の穴径Ｌ３を一定に設定し、立体網状構造体７０の部位を硬くするところは穴７２、７２間の距離Ｌ２を狭くし、立体網状構造体７０の部位を軟らかくするところは穴７２、７２間の距離Ｌ２を広く設定しても良い。 Instead of changing the hole diameter L3 of the hole 72 of the nozzle 71 as described above, the holes 72, 72 are set so that the hole diameter L3 of the hole 72 is set constant and the portion of the three-dimensional network structure 70 is hardened. The distance L2 between the holes 72 and 72 may be set wide to reduce the distance L2 between them and soften the portion of the three-dimensional network structure 70.
また、ノズル７１の穴７２の径Ｌ３及び穴７２、７２間の距離Ｌ２を変えることで、上記のように立体網状構造体７０の三方向の硬さを変化させることが出来る。 Further, by changing the diameter L3 of the hole 72 of the nozzle 71 and the distance L2 between the holes 72 and 72, the hardness in the three directions of the three-dimensional network structure 70 can be changed as described above.
その他の部材や製造方法は前記１乃至７と同様であるので、その説明を省略する。
また、前記実施例１乃至７と同様の作用、効果を奏する。
Since other members and manufacturing methods are the same as those in 1 to 7, the description thereof is omitted.
In addition, the same operations and effects as the first to seventh embodiments are obtained.
また、本実施例８においては、前記立体網状構造体７０を中心線７０ａほど軟らかく側部７０ｂほど硬く形成したことで人７５の中心ほど沈み易く、人７５の側部ほど沈み込みにくくなり、立体網状構造体７０は、その中心線７０ａに近いほど、人７５の体重を支え難く、その側部７０ｂに向うほど人７５の体重を支え易くなり、立体網状構造体７０の体圧分散性は向上する。 In the eighth embodiment, the three-dimensional network structure 70 is formed so that the center line 70a is softer and the side portions 70b are harder, so that the center of the person 75 is more likely to sink, and the side of the person 75 is less likely to sink. As the network structure 70 is closer to the center line 70a, the weight of the person 75 is less likely to be supported, and the weight of the person 75 is more easily supported toward the side portion 70b, and the body pressure dispersibility of the three-dimensional network structure 70 is improved. To do.
このように、立体網状構造体７０の横方向γについても硬さを変化させることにより、つまり、立体網状構造体７０の三方向において硬さを変化させることにより、より一層立体網状構造体７０の体圧分散性が向上する。 Thus, by changing the hardness also in the lateral direction γ of the three-dimensional network structure 70, that is, by changing the hardness in the three directions of the three-dimensional network structure 70, the three-dimensional network structure 70 is further improved. Body pressure dispersibility is improved.
前記実施例１乃至８のいずれの立体網状構造体１、５０、６０、７０も、従来のウレタンやばねなどを有するクッション体よりも構造が簡単で、かつ、軽量であるため、本発明の立体網状構造体１、５０、６０、７０を自動車やバイクなどのシートのクッション体として用いることにより、そのシートを軽量に製作でき、車体の軽量化につながり、自動車やバイク等の燃費の向上を図ることができ、環境面にも良い。 Any of the three-dimensional network structures 1, 50, 60, and 70 of Examples 1 to 8 are simpler in structure and lighter than conventional cushions having urethane or springs. By using the net-like structures 1, 50, 60, and 70 as cushion bodies for seats of automobiles, motorcycles, etc., the seats can be made lightweight, leading to weight reduction of the vehicle body, and improving fuel economy of automobiles, motorcycles, etc. Can be environmentally friendly.
本発明は、前記実施例のようなマットレスに適用できる外、椅子、ソファー、自動車・バイク等のシートなどのあらゆるクッション体としても適用可能である。 The present invention can be applied not only to the mattress as in the above embodiment, but also to any cushion body such as a seat for a chair, a sofa, an automobile or a motorcycle.
１、５０、６０、７０ 立体網状構造体
３ 線条
４ 溶着部（接触部）
５ 空隙
８ 表面
９ 裏面
１０ 押出成形機
１１、２１、３１、４１、７１ ノズル
１２、２２、３２、４２、７２ 穴
５１ 表層部
５２ 主体部
1, 50, 60, 70 Three-dimensional network structure 3 Wire 4 Welding part (contact part)
5 Gaps 8 Surface 9 Back 10 Extruder 11, 21, 31, 41, 71 Nozzle 12, 22, 32, 42, 72 Hole 51 Surface layer portion 52 Main portion
Claims (6)
該立体網状構造体を、その使用時における表面側が柔らかく、その裏面側が硬くなるように、該立体網状構造体の硬さを変化させて形成したことを特徴とする立体網状構造体。 A three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
A three-dimensional network structure formed by changing the hardness of the three-dimensional network structure so that the front side is soft and the back side is hard when used.
該立体網状構造体を、その使用時における表面側が柔らかく、その裏面側が硬くなるように、該立体網状構造体の硬さを変化させて、同時に一体成形したことを特徴とする立体網状構造体。 A three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
A three-dimensional network structure, wherein the three-dimensional network structure is integrally molded at the same time by changing the hardness of the three-dimensional network structure so that the front side is soft and the back side is hard when used.
該立体網状構造体を、その表裏方向の一方の面側から他方の面側に向かって硬さを徐々に変化させて、同時に一体成形したことを特徴とする立体網状構造体。 A three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
A three-dimensional network structure, wherein the three-dimensional network structure is integrally molded at the same time by gradually changing the hardness from one surface side to the other surface side in the front and back direction.
該立体網状構造体を、その使用時における表面側に表層部を設け、該表層部の下部に主体部を設け、前記表層部と前記主体部を一体に形成し、
該主体部の前記表面側が柔らかく、前記裏面側が硬くなるように、該主体部の硬さを変化させて形成し、
前記表層部を、前記主体部の前記表面側よりも硬く形成したことを特徴とする立体網状構造体。 A three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The three-dimensional network structure is provided with a surface layer portion on the surface side in use, a main body portion is provided below the surface layer portion, and the surface layer portion and the main body portion are integrally formed,
The main body is formed by changing the hardness of the main body so that the front side is soft and the back side is hard,
The three-dimensional network structure characterized in that the surface layer portion is harder than the surface side of the main body portion.
ノズルに形成した複数の穴の間隔及び／又は穴径を、成形される立体網状構造体の使用時における表裏方向及び／又は該表裏方向と直交する方向に対応して変え、
前記ノズルの複数の穴から樹脂を押出して前記線条を形成し、前記立体網状構造体を、その表裏方向及び／又は該表裏方向と直交する方向の硬さを変化させて一体に形成することを特徴とする立体網状構造体の製造方法。 A method for producing a three-dimensional network structure in which a plurality of resin filaments are three-dimensionally irregularly entangled and partially fused,
The interval between the plurality of holes formed in the nozzle and / or the hole diameter is changed in accordance with the front and back direction and / or the direction perpendicular to the front and back direction when using the molded three-dimensional network structure,
Resin is extruded from a plurality of holes of the nozzle to form the filament, and the three-dimensional network structure is integrally formed by changing the front and back direction and / or the hardness in the direction orthogonal to the front and back direction. A method for producing a three-dimensional network structure characterized by the above.
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