[0001] 1. Field of the Invention
[0002] The invention relates to an elastic product including a stuffed toy, a bed, a mattress, a pillow, a cushion, and the like and to an elastic product for use in a sofa, a chair or the like. More specifically, the invention relates to an elastic product that can have a unique marshmallow-like elastic feel and that can make people relaxed when they touch it even in an emotional state.
[0003] 2. Description of the Related Art
[0004] Some stuffed toys comprise a fabric bag having an animal-like shape or the like and a material such as cotton and polyurethane stuffed therein, as disclosed in U.S. Design Pat. Nos. 457,928 (stuffed toy), 456,468 (stuffed toy potbelly pig), 454,927 (stuffed toy character), and 453,362 (penguin pilot stuffed toy).
[0005] In such stuffed toys, however, the bag has poor stretching properties with a simple view to maintaining its shape. In such stuffed toys, the bag is fully stuffed with cotton or the like, and therefore they are not freely flexible and have a limited amusing purpose. They can only give a feel of the bag material such as towel fabric, and its relaxing feel can only be derived from that.
[0006] Some beds or mattresses for sitting or sleeping contain expanded polystyrene particles for allowing some flexibility. For example, Japanese Utility Model Application Laid-Open (JP-U) No. 56-115966 discloses a cushion containing expanded particles 5 to 20 mm in diameter. JP-U No. 03-45641 discloses a mat filled with expanded polystyrene particles 1 to 5 mm in size. Japanese Patent No. 3057059 discloses a sofa filled with expanded polystyrene particles about 1 to 2 mm in diameter.
[0007] In such disclosed elastic products, however, the bag material is not carefully selected, and the diameter of the expanded polystyrene filling is so large that it can be poor in mobility or fluidity (lubricity). The expanded polystyrene with a relatively large diameter can disadvantageously cause an odd sound “squeak” when allowed to move or flow. In addition, the expanded polystyrene cannot be used at a hot season because it has a large number of cells and therefore high thermal storage capacity.
[0008] The invention has been made in light of these problems. It is an object of the invention to provide an elastic product comprising a bag with increased stretchability that permits large deformation and containing a filling material with increased fluidity that can prevent the odd sound when the product is deformed. It is another object of the invention to provide an elastic product comprising a foamed material with decreased thermal storage capacity, which can be used in contact with skin even in a high-temperature season.
[0009] The inventors have carefully examined combinations of expanded particles different in diameter and various types of fabrics and found that a specific fabric pack containing expanded particles with a specific diameter can give a very good feel to a user, in completing the invention. The inventors have also coated raw beads with an appropriate film. As a result, expanded particles with significantly increased fluidity have been provided, which can be prevented from causing an odd sound. The inventors have also formed a metal film on the front and/or back surface of the bag fabric to solve the thermal storage problem with the elastic product.
[0010] Thus, the invention is directed to an elastic product, comprising: expanded particles having an average diameter of 0.1 to 1.0 mm; and a bag which comprises a two-way tricot fabric with a thickness of 0.3 to 1.5 mm and in which the particles are packed, wherein a rectangular test specimen of the tricot fabric having a size of 16 cm in the warp direction and a size of 2.5 cm in the fill direction shows an extension percentage of 250% to 300% when a tension of 1 kilogram-force is applied to the test specimen in the warp direction.
[0011] According to the invention, the combination of the expanded particles with the specific particle diameter and the two-way tricot fabric can provide an excellent match between the fluidity of the expanded particles and the stretching properties of the fabric so that a unique marshmallow-like elastic feel can be achieved. Numbers of monitor tests have demonstrated that the inventive elastic product can offer a unique feel and make people relaxed when they touch it even in an emotional state.
[0012] For example, the elastic product may be a stuffed toy, a bed, a mattress, a pillow, a cushion, or the like. The elastic product may also be a component for use in a sofa, a chair or the like. There may be two manners of the relationship between the invention and the completed product or the component: The above product or the component may be made up only of the inventive elastic product or made up of a combination of the inventive elastic product and any other component(s).
[0013] In the invention, the expanded particles may be packed in a single bag, or packed in a first bag, which may then be packed in a second bag. In such cases, each bag comprises a two-way tricot fabric. On the other hand, two thicknesses of two-way tricot fabrics may be used to form a single bag.
[0014] In the invention, the thickness of the two-way tricot fabric is from 0.3 to 1.5 mm, preferably less than 1 mm, more preferably from 0.5 to 0.6 mm. In particular, the outermost fabric, which will be touched by the user, preferably has a thickness of 0.5 to 0.6 mm.
[0015] In the invention, the expanded particles have an average diameter of 0.1 to 1.0 mm. The average diameter may mean an equivalent diameter calculated through the conversion of each particle shape into a sphere. If the expanded particles have an average diameter of more than 1 mm, the frictional force between the particles can be so high that the fluidity of the particles can be reduced. The expanded particles with an average diameter of less than 0.1 mm can have good fluidity but are not appropriate because they can leak out through the interstices of the fabric when the fabric is stretched. In the invention, the expanded particles more preferably have a particle diameter (an average diameter) of about 0.4 to 0.9 mm.
[0016] In the invention, the expanded particles are preferably a product of the pre-expansion of raw beads, more preferably a pre-expanded product prepared by pre-expansion of beads according to an expanded bead polystyrene (EPS) process. In such a process, the surfaces of 100 parts by weight of raw beads are preferably coated with 0.5 to 1.5 parts by weight of a flow-promoting agent. The flow-promoting agent may be a salt of a fatty acid(s) and a metal(s). The fatty acid(s) may be at least one selected from stearic acid, ethylene bis stearic acid, lauric acid, and palmitic acid, and the metal(s) may be at least one selected from magnesium, calcium, zinc, barium, and aluminum.
[0017] The inventive product typically uses a two-way tricot fabric having a warp knitted (tricot) structure of a nylon or polyester yarn in which a polyurethane yarn is inserted. Preferably selected is a combination of 90 to 75% by weight of a nylon or polyester yarn and 10 to 25% by weight of a polyurethane yarn.
[0018] In any mode of the invention, a rectangular test specimen of the two-way tricot fabric having a size of 16 cm in the warp direction and a size of 2.5 cm in the fill direction shows an extension percentage of 250 to 300% when a tension of 1 kilogram-force is applied to the test specimen in the warp direction. In the inventive elastic product, the bag can have an extension percentage of 250 to 300%. Hence the user can feel the inner particles in a straightforward manner and can have a unique feel when the user presses her or his fingertip against the elastic product or holds it by hand. If the extension percentage in the warp direction is less than 250%, such a feel cannot be provided.
[0019] The inventive elastic product with high extensibility may be applied to a stuffed toy with elongated hands and feet for amusement. For example, such a stuffed toy may have a shape as shown in
[0020] According to the invention, the two-way tricot fabric exhibits an extension percentage of 250 to 300% in the warp direction under a tension of 1 kilogram-force. In a preferred mode, a rectangular test specimen of the fabric having a size of 16 cm in the fill direction and a size of 2.5 cm in the warp direction shows an extension percentage of 100 to 140% in the fill direction when a tension of 1 kilogram-force is applied to the specimen in the fill direction. In a preferred mode, the extension percentage slightly increases with the tensile force, but a too much increase in the extension percentage is not appropriate. Under a tension of 3 kilograms-force, the extension percentage is preferably about 340 to 380% in the warp direction and about 140 to 180% in the fill direction. In such a case, two types of test specimens cut from the fabric in sizes 16 cm×2.5 cm and 2.5 cm×16 cm, respectively, are also used in the determination of the value, wherein the test specimen with a size of 16 cm in the warp direction is extended in the warp direction and the test specimen with a size of 16 cm in the fill direction is extended in the fill direction.
[0021] In a preferred mode of the invention, a metal film is formed on the surface of the two-way tricot fabric. In such a case, heat can be dissipated from the bag of the inventive elastic product used even as or in a bed, mattress, cushion, sofa, chair, or the like, so that the thermal storage problem with the expanded particles can be resolved. Examples of the material for the metal film include but are not limited to aluminum, stainless steel and titanium. In terms of resistance to corrosion and easy processing, titanium is particularly preferred. The titanium film should be formed with a thickness in the range of 50 to 2000 Å. A thickness of at least 250 Å should be selected for the effect of sufficient thermal conductivity, and a thickness of about 300 to 500 Å is preferred in view of feel to skin.
[0022] A plurality of the inventive elastic products may preferably be used in a housing bag. In such a case, part of the housing bag may be made of a material lacking in stretchability, and the inventive elastic products may preferably be used in a bed, a mattress, a pillow, a sofa, or a chair. In a preferred manner, the elastic product for use in the bed, mattress or pillow is substantially cylindrical and placed or arranged in such a manner that its axial direction will be perpendicular to the height direction of the user.
[0023] When the inventive elastic products are used in a bed, a mattress, a pillow, or the like, part of the back face of the housing bag may preferably be connected to part of the front face of the housing bag so that the space for holding the respective elastic products is divided in the height direction of the user. In such a case, a user-facing upper portion of the housing bag preferably comprises a highly stretchable portion, which is divided in the height direction of the user by a portion lacking in stretchability.
[0024] A single piece of the elastic product may be packed in a housing bag to form a pillow. In such a case, the elastic product preferably has a boundary portion for inhibiting a shift of the expanded particles in the height direction of the user.
[0025] In a bed, a mattress or the like, the inventive elastic product may be used only at a portion that will be in contact with the head of the user.
[0026] FIGS.
[0027] FIGS.
[0028] FIGS.
[0029]
[0030]
[0031]
[0032] FIGS.
[0033] FIGS.
[0034] FIGS.
[0035]
[0036] FIGS.
[0037]
[0038] Embodiments of the invention are described in detail with reference to the examples below. FIGS.
[0039] Referring to the drawings, the cushion
[0040] The expanded particles housed in the bag
[0041] The expanded bead polystyrene (also called styrofoam) is generally manufactured by a process including (a) a pre-expanding step in which raw beads about 0.3 to 2 mm in diameter are heated to be expanded by about 10 to 90 times; (b) a drying and aging step in which the pre-expanded beads are allowed to stand in an aging silo for six hours or more so that air is allowed to infiltrate into the cells and that the pre-expanded beads are allowed to be in a stable state; and (c) an expanding and molding step in which the aged pre-expanded beads are charged into a mold of a molding machine and expanded again and fused by steam at a temperature of 115° C. to 125° C. This example uses the pre-expanded particles, which are provided before the final expanding and molding step.
[0042] The raw beads may be made of polystyrene resin, polyethylene resin, polypropylene resin, or the like, and preferably made of a polystyrene resin impregnated with a hydrocarbon blowing agent or the like. Particularly preferred is a polystyrene resin in which the residual styrene monomer content is reduced to 500 ppm. Such a polystyrene resin can form a cushion without fear of sick house syndrome (air pollution in houses).
[0043] The surfaces of 100 parts by weight of the raw beads are coated with 0.5 to 1.5 parts by weight of the flow-promoting agent, which serves as a lubricant when the expanded particles are allowed to move. The flow-promoting agent is effective in inhibiting an odd sound, which would otherwise be caused by friction between the expanded particles.
[0044] Preferred examples of the flow-promoting agent include a salt of a fatty acid and a metal, fatty acid amine, sorbitan fatty acid ester, aluminum hydroxide, talc, calcium carbonate, and polyethylene wax. Examples of the fatty acid include stearic acid, ethylene bis stearic acid, lauric acid, and palmitic acid. Examples of the metal include magnesium, calcium, zinc, barium, and aluminum.
[0045] Particularly preferred examples of the flow-promoting agent include zinc stearate, calcium stearate and magnesium stearate. The content of the agent should be from 0.5 to 1.5 parts by weight, preferably from 0.6 to 1.2 parts by weight, based on 100 parts by weight of the raw beads. If the content of the flow-promoting agent is less than 0.5 parts by weight, the odd sound-inhibiting effect can be insufficient. An increase in the effect may not be expected at a content of more than 1.5 parts by weight.
[0046] Butane or pentane is preferably used as the blowing agent. Cyclohexane is preferably used as a blowing assistant. The contents of polystyrene, butane or pentane and cyclohexane are preferably but not limited to 90 to 97% by weight, 3.0 to 8.0% by weight and 0 to 2.0% by weight, respectively.
[0047] The raw beads with such a composition are heated at a temperature of about 80° C. to 100° C. using steam or the like so that they are expanded by the expansion of the blowing agent. In this example, the expansion ratio is set at about 10 to 80 times, and the expanded particles are substantially spherical and controlled to have diameters of about 0.4 to 0.9 mm.
[0048] In this example, the particles expanded by the expansion of the blowing agent are allowed to rise by hot air at a specific pressure and introduced into an aging silo. In such a process, the hot air allows the expanded particles to move up by about 11 m and then to come into the aging silo. Until the particles are introduced in the silo, therefore, the surface of the expanded particles are dried and dewatered, and the replacement of the blowing agent by air is accelerated inside the expanded particles. Such a process also allows particle size selection to some extent so that expanded particles substantially uniform in diameter can be collected.
[0049] The process of completing the cushion
[0050] The inner and outer fabrics
[0051] In this example, the two-way tricot fabric achieves sufficient stretching properties in the length and width directions, and the outer fabric
[0052] A specific extension percentage is also selected. Specifically, two types of test specimens in a size of 16 cm×2.5 cm are cut from the fabric, and one side of each specimen is pulled under a specific tension with the opposite side fixed. Through such a test, a fabric with a certain extension percentage as shown below is selected. Under a tension of 1 kilogram-force, the extension percentage should preferably be about 260 to 295% in the warp direction and about 105 to 135% in the fill direction; Under a tension of 1.5 kilograms-force, the extension percentage should preferably be about 290 to 320% in the warp direction and about 120 to 150% in the fill direction; Under a tension of 2.25 kilograms-force, the extension percentage should preferably be about 320 to 350% in the warp direction and about
[0053] The bag
[0054] FIGS.
[0055] The second example has substantially the same principal structure as the first embodiment. In this example, a titanium film is formed on the whole surface of the outer fabric
[0056] The stuffed toy
[0057] FIGS.
[0058] The inner bags
[0059] Referring to
[0060] In the outer bag
[0061] The pillow PL has different heights. For example, the front and back sides
[0062] The effective height of the tie strip
[0063] The two stretchable fabrics
[0064] In this example, the stretchable fabrics
[0065] Referring to
[0066] The two inner bags
[0067] Next, a description is provided of the working state of the restful sleep pillow PL according to the example. Referring to
[0068] However, the four sides of the outer bag
[0069] The pillow PL may be used in direct contact with the head or may be used via a pillow cover. The pillow cover is preferably made of a pile material. Herein, the pile material means a fabric whose surface has a dense feather texture, a towel fabric whose surface has fine loops, or the like, including velveteen, corduroy and velvet.
[0070] The effectiveness of the above-described pillow PL has been demonstrated by a test and evaluation result report by Consumer Product End-Use Research Institute Co., Ltd. The test was carried out as shown below.
[0071] Body Pressure Dispersion Test
[0072] The pillow PL according to the example and a conventional product were subjected to the test. A body pressure sensor was placed under each test product, on which the subject (user) put the head when the pressure was measured. The conventional product was a Tempur® pillow, which has been suggested to form a best balanced support for the human body by its deformation depending on the body temperature and pressure.
[0073] In the test environment at 18±2° C. and 55±5%RH, the pressure was measured with or without a pillow cover attached to each test product. The subject was a woman in her twenties, and the comparison between the tests was performed on the same person. The test results are shown in FIGS.
[0074] Each drawing three-dimensionally shows the values measured by the pressure sensor. From the comparison between FIGS.
[0075] Up to this point, the description is provided of the third example of the invention. The above specific description is not intended to limit the scope of the invention. For example, the fourth example of the invention including small and large inner bags
[0076] When two separate inner bags are integrated as shown in
[0077]
[0078] The boundary portion
[0079]
[0080] In the sixth example, a rectangular boundary portion
[0081] While preferred embodiments of the invention have been shown and described above, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention.