Pillow cushion and method for manufacturing pillow cushion

Abstract

A pillow cushion is provided in which a repulsive force is unlikely to concentrate on an area in the vicinity of the apex of a back head portion and thus the head of a user is easily stabilized. In the pillow cushion formed with a filament three-dimensional bonded member in which, in a state where a plurality of filaments formed of a thermoplastic resin or a thermoplastic elastomer are three-dimensionally entangled, contact points of the filaments are fused, the density of the filaments in a back head portion support region is higher in both end portions in the direction of left and right shoulders than in a center portion.

1 . A pillow cushion formed with a filament three-dimensional bonded member in which, in a state where a plurality of filaments formed of a thermoplastic resin or a thermoplastic elastomer are three-dimensionally entangled, contact points of the filaments are fused,
 wherein a density of the filaments in a back head portion support region is higher in both end portions in a direction of left and right shoulders than in a center portion.   
     
     
         2 . The pillow cushion according to  claim 1 ,
 wherein the density of the filaments in the back head portion support region is gradually increased from the center portion toward the both end portions in the direction of left and right shoulders.   
     
     
         3 . The pillow cushion according to  claim 2 ,
 wherein the density of the filaments in the back head portion support region is gradually increased from the center portion toward both end portions in a height direction.   
     
     
         4 . The pillow cushion according to  claim 3 ,
 wherein the pillow cushion is formed by stacking a plurality of pillow units in a thickness direction,   each of the pillow units includes a first pillow unit and a second pillow unit formed with the filament three-dimensional bonded member,   a density of the filaments in the back head portion support region of the first pillow unit is gradually increased from the center portion toward the both end portions in the direction of left and right shoulders and   a density of the filaments in the back head portion support region of the second pillow unit is gradually increased from the center portion toward the both end portions in the height direction.   
     
     
         5 . A method for manufacturing the pillow cushion according to  claim 2 , the method comprising:
 a molten filament supply step of discharging a plurality of molten filaments formed of a thermoplastic resin or a thermoplastic elastomer downward in a vertical direction from a plurality of nozzle holes provided in a nozzle portion;   a filament three-dimensional fused member formation step of fusing, while three-dimensionally entangling the molten filaments, contact points of the molten filaments to form a filament three-dimensional fused member; and   a filament three-dimensional bonded member formation step of conveying the filament three-dimensional fused member and moving the filament three-dimensional fused member in cooling water to cool and solidify the filament three-dimensional fused member,   wherein the pillow cushion according to  claim 2  is manufactured by cutting the filament three-dimensional bonded member formed in the filament three-dimensional bonded member formation step,   the direction of left and right shoulders in the pillow cushion is substantially aligned with a direction of the conveyance and   a speed of the conveyance is controlled such that the density of the filaments in the back head portion support region of the pillow cushion is gradually increased from the center portion toward the both end portions in the direction of left and right shoulders.   
     
     
         6 . The manufacturing method according to  claim 5 ,
 wherein the pillow cushion that is used by a predetermined user is manufactured, and   the speed of the conveyance is controlled based on back head portion horizontal shape information of the user such that the density of the filaments in the back head portion support region of the pillow cushion is gradually increased from the center portion toward the both end portions in the direction of left and right shoulders.   
     
     
         7 . The manufacturing method according to  claim 6 ,
 wherein the pillow cushion in which the density of the filaments in the back head portion support region is gradually increased from the center portion toward both end portions in a height direction is manufactured, and   a density of the nozzle holes in the nozzle portion is adjusted based on back head portion vertical shape information of the user such that the density of the filaments in the back head portion support region of the pillow cushion is gradually increased from the center portion toward the both end portions in the height direction.   
     
     
         8 . The manufacturing method according to  claim 6 ,
 wherein the speed of the conveyance is controlled based on back head portion position information and head weight information of the user.   
     
     
         9 . A method for manufacturing the pillow cushion according to  claim 3 , the method comprising:
 a molten filament supply step of discharging a plurality of molten filaments formed of a thermoplastic resin or a thermoplastic elastomer downward in a vertical direction from a plurality of nozzle holes provided in a nozzle portion;   a filament three-dimensional fused member formation step of fusing, while three-dimensionally entangling the molten filaments, contact points of the molten filaments to form a filament three-dimensional fused member; and   a filament three-dimensional bonded member formation step of conveying the filament three-dimensional fused member and moving the filament three-dimensional fused member in cooling water to cool and solidify the filament three-dimensional fused member,   wherein the pillow cushion according to  claim 3  is manufactured by cutting the filament three-dimensional bonded member formed in the filament three-dimensional bonded member formation step,   the direction of left and right shoulders in the pillow cushion is substantially aligned with a direction of the conveyance and   a speed of the conveyance is controlled such that the density of the filaments in the back head portion support region of the pillow cushion is gradually increased from the center portion toward the both end portions in the direction of left and right shoulders.   
     
     
         10 . The manufacturing method according to  claim 7 ,
 wherein the speed of the conveyance is controlled based on back head portion position information and head weight information of the user.