CUSHION MAT

Abstract: A mat (1) is formed by sandwiching a core (3) of a synthetic resin between cushioning layers (6), (7) so as to obtain a cushion mat without using metal members such as coiled springs. Therefore, this mat is lightweight and free from the occurrence of rust. Since the core (3) is formed by unitarily connecting vertical walls (21) and (21) by alternating upper and lower horizontal walls (22) and (23), and providing bulging portions (27) at regular intervals on each of the vertical walls (21), the mat has an excellent strength and a good gas-permeability and can be used more comfortably in practice.

Description: TECHNICAL FIELD The present invention relates to a cushion mattress, which is used for a mattress or a bed. TECHNICAL BACKGROUND A conventional cushion mattress for a bed is constructed such that a number of coil springs are fixed to a metal frame under the both surfaces, overlaid by sheet materials respectively on both sides and covered by cloth entirely. In such a kind of mattress, however, since a metal frame and a number of coil springs are incorporated, the gross weight becomes greater and handling is inconvenient. Also, the coil springs and metal frame are not only prominent causes of rust but also for breakage of the sheet material and the cover cloth, negatively affecting the durability of the mattress and the user's comfort. Moreover, in this kind of bed mattress, as importance is laid only on how to support the body stably, the function of improving health is hardly considered, It is the object of the invention to provide a light-weight mattress and improve the durability of the mattress, by forming a cushion mattress, particularly for a bed, without using a metal component such as a coil spring. It is another object of the invention to improve the durability of the cushion mattress, the user's comfort and the health of the user by employing a core portion with a special structure. DISCLOSURE OF THE INVENTION The invention relates to a cushion mattress having an elastic mattress body covered throughout its periphery by a cover, and formed with the core portion consisting of synthetic resin moldings having rigidity and an elastic surface layer, overlaid on both sides of the core portion sandwiched between them. The said core portion is formed with vertical side-walls at regular intervals and horizontal upper-end walls and lower-end walls connected mutually between the upper-end and the lower-end of the vertical side-walls side by side, said vertical side walls are formed into a corrugated surface (26) which includes protrusions (27) which extend vertically in parallel to each other at constant intervals, forming interposing depressions (28) therebetween. In reference to the invention, since a metal member such as a coil spring is not used, the whole mattress is light and easy to handle, and also rusting and breakage of the cover cloth does not occur, thus the durability of the mattress and user's feeling are not compromised. Furthermore, since the whole mattress is comprised of the core portion of synthetic resin moldings which are rigid and the core portion is formed with a special structure, it is not subject to breakage or deformation by an external force, improving the durability. Also, since the core portion has the function of preventing the body from sinking down, the body may be supported in its natural form, thus a quiet sleep is insured. Also, the core portion has a hollow structure, which is good for ventilation and 1damp-proofing to improve the user's feeling and health with the function of keeping the natural form of the body. BRIEF DESCRIPTION OF THE INVENTION Fig. 1 is a perspective view showing a cushion mattress for a bed with a partly broken cover according to one embodiment of the present invention, Fig. 2 is a sectional view taken along the line A-A of Fig.1, Fig 3 is a perspective view showing a lamination structure of a mattress body, each of the layers being broken, Fig. 4 is a perspective view showing a enlarged core portion, Fig. 5 is a sectional view showing an enlarged second cushion layer, Fig. 6 is a perspective view of a cushion mattress for a bed with a cover partly broken according to another embodiment of the invention, Fig. 7 is as perspective view of a cushion mattress for laying our on the floor, with a cover and a surface layer partly broken according to another embodiment of the invention, Fig. 8 is a sectional view taken along the line B-B of Fig. 7. BEST MODE FOR CARRYING OUT THE INVENTION Fig. 1 and 2 show a cushion mattress for a bed according to one embodiment of the invention constructed such that the entire periphery of an elastic mattress body 1 is covered by a cloth cover 2. The mattress body 1, as shown in Fig. 2 and 3, is composed of overlapping elastic surface layers 6, 7 on both sides of a core portion 3 sandwiched between them, and surrounding these laminations is circumference wall 8. The core portion 3 and respective surface layers 6, 7 , and the circumferential wall 8 are bonded into a unit by means of adhesives. The core portion 3 is formed of synthetic resin having rigidity, and accounts for 50% of the mattress body 1's thickness. The core portion 3 not only serves to lighten the mattress also serves as the rigid core, thus preventing deformation of the entire mattress. The core portion 3, as shown in Fig. 4, is constructed such that many vertical side walls 21 are provided at equal intervals inside the circumference wall 20 surrounding the sides. Upper ends and lower ends of the adjoining vertical side walls 21 are connected alternately by a horizontal upper wall 22 and a horizontal lower wall 23. The circumference wall 20, each vertical side walls 21, each horizontal upper walls 22 and each horizontal lower walls 23 are formed into an unit, wherein a hollow groove 24 open in the upper portion is formed between the horizontal lower wall 23 and the vertical side walls 21, 21 thereabove, and a hollow groove 25 open in the lower portion is formed between the horizontal upper wall 22 and the vertical side walls 21, 21 thereunder. By the presence of the hollow grooves 24, 25, the ventilation and dehumidifying effects are improved and the core portion 3 becomes lighter. Each of the vertical side walls 21 are formed into a corrugated surface 26, thereby the strength of the vertical side wall 21 is considerably increased. The corrugated surface 26 includes protrusions 27 which extend vertically in parallel to each other at constant intervals, forming interposing depressions 28 there-between. The surface layers 6, 7 respectively include tough protecting plates 4, 5 employed in the upper and lower positions to sandwich the core portion 3. In the protecting plate 4 on the surface side, a tough synthetic resin plate such as polyethylene which is not readily deformable is used to protect the core portion 3 from immoderate forces exerted by a body, and to prevent the body from sinking against elastic surface layer 6. As for protecting plate 4, compressed plywood may be used in the place of synthetic resin plate, if it is strong enough. The protecting plate 5 on the bottom side is for protecting the core portion 3 in the same way as the protecting plate 4 on the surface side, and the said synthetic resin plate is usually used. However when the upper and lower portion of the mattress is fixed in this way, though the strength may be small, a paper bard (e.g. corrugated fiberboard) which is light and has a hygroscopic properties can be used. The surface layer 6 on the surface side, in the case of this embodiment, has a three-layer structure of different types of cushion materials, comprising a first cushion layer 10 on the bottom, a second cushion layer 11 on the top and a third cushion layer 12 in the center. The first cushion layer 10 is formed by a soft air permeable cushion material such as a soft urethane foam, and gives strong elasticity to the body by deforming elastically sufficiently against the load. The second cushion layer 11 is formed by a semihard air permeable cushion material such as a semihard urethane foam, and supports the body by deforming slightly against the load. The cushion material is formed into a semihard body by impregnating the semihard polyurethane foam entirely with rubber latex and drying by heating to harden the rubber latex. The entire surface of the cushion material is formed with a depression-and-protrusion surface 13, whose respective protrusions 14 include a hardened portion 15 as shown in Fig. 5. The hardened portion 15 is formed by impregnating the rubber latex only on the apex of the protrusion 14 and is hardened by the same heating and drying process. By the presence of the hardened portion 15, the protrusions 14 are not crushed by the pressure and the body is supported by point contact, so that air permeability is improved by gaps produced between the body and the cushion material and also a finger-pressure force may be applied to the body. The third cushion layer 12 is formed by a cushion material constructed by pressing and hardening urethane chips while heating, whereby the body is supported with a mild elasticity and the surface layer 6 is strengthened. The bottom side surface layer 7 is formed by a same material as the first cushion layer 10, namely, by the soft air permeable cushion material 16 such as the soft urethane foam. The soft cushion material 16 provides a strong elasticity to the body by deforming elastically against the load sufficiently. The circumferential wall 8 is also formed by the same soft cushion material, protecting the laminate structure of the mattress body from the circumference. Fig. 6 shows another embodiment of the invention, in which a number of permanent magnets 17 are disposed on the surface side of surface layer 6 of the mattress body 1. The permanent magnets 17 are fixed to the depressions of the depression-and-protrusion surface 13 on the second cushion layer 11 by adhesives for the purpose of applying lines of magnetic force to the body to obtain a predetermined magnetic treatment effect. Fig. 7 and 8 shows another embodiment of the invention, which is a cushion mattress for laying out on the floor. This type of cushion mattress is constituted by overlapping surface layers 6, 7 comprising semihard cushion material which sandwiches the core portion 3 having same structure as the above said core portion. Also, the circumference of the face layers 6,7 are adhered to each other, which is covered by a cloth cover 2. Also, a number of permanent magnets 17 are disposed and fixed with adhesives on the surface layer 6 on the surface side. INDUSTRIAL APPLICABILITY A cushion mattress for a bed as shown in Fig. 1 is used so that it is arranged on a bed and covered with a thin bed sheet. When a person lies on the mattress, a suitable elasticity is given mainly by a first cushion layer 10, on the surface side surface layer 6 and soft cushion material 16 on the bottom side surface layer 7, and the body is supported by a second cushion layer 11. In this case, a protecting plate 4 and the core portion 3 on the surface side supports the body in a natural form against the elastic deformation of the surface layer 6 such that it will sink down in an unnatural form, insuring a quiet sleep. Also, when the downward load is applied on the core portion 3, though it operates on the horizontal upper wall 22, vertical side wall 21 and horizontal lower wall 23, the protrusions 27 on the vertical side wall 21 serve as ribs, the strength is increased to support it sufficiently against the concentrated loads. Also, even when the load is applied downward obliquely, the adjoining vertical side walls 21, 21 cooperate to prevent deformation and the protrusions 27 prevent the vertical side wall 21, from bending under loads. On the second cushion layer 11, since there is provided a hardened portion 15 on each of the protrusions 14 of the depression-and-protrusion surface 13, the protrusions 14 are not crushed by the loads and the body is supported in point contact by the hardened portion 15 of the respective protrusions 14. Accordingly, gaps produced between the body and the second cushion layer 11 improves not only the ventilation and the dehumidifying effect but also comfort of the user. In addition, the protrusions 14 of the depression-and-protrusion surface 13 presses the right places of the body to provide the finger-pressure, resulting in improving the circulation of the blood and health. Moreover, in the embodiment shown in Fig. 6, lines of magnetic force emitted from permanents magnet 16 operate on the body to further improve the circulation of the blood, thereby eliminating stiff shoulders and reducing fatigue. When transporting such a mattress, since metal members are not used in the mattress body 1 and hollow synthetic resin moldings are used as the core portion 3, the whole mattress may be made lighter and it can be handled easily. Also, there is no problem of rust or breakage, thus good durability and user's comfort can be realized. A cushion sheet as shown in Fig. 7 is used as a mattress for laying out on the floor and regarding the function of the core portion 3, it is the same as the embodiment shown in Fig. 1 and the explanation of it is omitted here.

Claims: A cushion mattress having an elastic mattress body (1) covered entirely with a cover (2): said mattress body (1) being formed with a core portion (3) consisting of synthetic resin moldings having rigidity and elastic surface layers (6), (7) overlaid on both sides of the core portion (3) sandwiched therebetween, said core portion (3) is formed with vertical side-walls (21) at regular intervals and upper ends and lower ends of the adjoining vertical side walls (21),(21) are connected alternately by a horizontal upper wall (22) and horizontal lower wall (23), said vertical walls (21) are formed into a corrugated surface (26) which includes protrussions (27) which extend vertically in parallel to each other at constant intervals, forming interposing depressions (28) therebetween. A cushion mattress as claimed in claim 1, wherein each surface layers (6), (7) respectively includes tough protecting plates (4),(5) disposed in the upper and the lower positions of the core portion (3) sandwiched therebetween. A cushion mattress as claimed in claim 1 or 2, wherein the surface layer (6) on the surface side has a plural cushion layer (10), (11), (12) of different type of cushion materials. A cushion mattress as claimed in one of claim 1-3, wherein the surface layer (6) on the surface side provides a number of permanent magnets (17) with its surface.

Inventors: MASUDA ISAMU, MASUDA, ISAMU
Applicants: NIHON KENKOZOSHIN KENKYUKAI KK, NIHONKENKOZOSHINKENKYUKAI CO. LTD.
Application year: 1990
Main classification: A47C27
IPC codes: A47C27