JP2000350639A - Sofa and manufacture of sofa - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily secure a sufficient reinforcing effect by integrally inserting/ adhering a reinforcing plate into/to the interior of a slit reaching core material both side surfaces by opening in a core material under surface in the reverse vicinity of a back rest part in a sofa using a synthetic resin foam and a rubber foam having cushioning performance as a core material. SOLUTION: A sofa core material 1 is composed of a synthetic resin foam and a rubber foam having cushioning performance, and is composed of a seat part 3 and a back rest part 2. In this case, a slit 8 opening in a core material under surface by reaching core material both side surfaces 6, 6' is formed inside from the reverse 7 of the back rest part 2, and a reinforcing plate 5 is inserted its interior to be integrally adhered with the core material 1. Plywood, a metallic plate, a synthetic resin plate, a corrugated board and cardboard can be used as the reinforcing plate 5, and the corrugated board and the cardboard are excellent when considering cost, a processing property and recycling performance, and the corrugated board and the cardboard are also excellent from the viewpoint of improving strength more than the strength of paper alone by use of an adhesive.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a synthetic resin foam or rubber foam having cushioning properties as a core material,
The present invention relates to a sofa having a seat and a backrest formed thereon, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, rubber foams such as synthetic resin foams and synthetic rubber foams having cushioning properties such as soft polyurethane foams and soft polyethylene foams have been used as core materials, and seats and backrests have been formed. A sofa is used in which a core material is covered with a covering material such as a cloth material or a leather material.

This kind of sofa is easy to obtain a cushioning core material having appropriate cushioning property and hardness from a synthetic resin foam or a rubber foam, and a synthetic resin foam or a rubber foam is processed. Sofas can be manufactured relatively inexpensively because of their features such as ease of use, synthetic resin foam or rubber foam alone, and shape retention that can withstand use strength by taking simple reinforcement measures. It has been used as a sofa for a long time.

[0004]

By the way, this type of sofa using a synthetic resin foam or rubber foam having a cushioning property, if the hardness of the synthetic resin foam or rubber foam serving as a core material is moderate, It is a structure that can withstand the use of synthetic resin foam or rubber foam alone without any reinforcement, but in this case, the cushioning property is impaired, or the synthetic resin foam or rubber foam density increases, There are problems such as an increase in the weight of the sofa and an increase in cost.

In some cases, a strong reinforcing material such as a steel pipe is embedded in a synthetic resin foam or rubber foam core material to reinforce the material. In this case, the reinforcing effect is sufficient, but the material cost is low. However, there is a problem in that the production cost is high because the cost is high and the processability is low, and the weight of the sofa is further increased.

In order to make use of the appropriate cushioning properties of synthetic resin foams or rubber foams, and to take advantage of their lightness, a synthetic resin foam or rubber foam having a moderate hardness is used as a core material, and a cloth material or the like is provided outside the core material. Reinforcement is also performed by bonding and integrating cardboard. In the conventional example shown in FIG. 4, the seat portion (11) and the backrest portion (1) are made of cushioning synthetic resin foam or rubber foam.
0) is formed, and a thick cardboard (13) is adhered and integrated to the back surface (12) of the backrest (10) to reinforce it. In this case, although the effect of reinforcing the load on the backrest (10) is sufficient, the portion of the lower part of the reinforcing material (13) that contacts the floor is easily damaged, and the reinforcing material is deformed and the reinforcing effect is lost. There is a problem that the reinforcing material (13) is exposed on the back surface of the backrest portion, so that the durability is reduced due to abrasion or the like.

The present invention is to provide a sofa which can obtain a sufficient reinforcing effect and has excellent durability even by simple reinforcement using such a reinforcing plate, and an efficient manufacturing method thereof. To provide.

[0008]

A sofa according to claim 1 of the present invention is a sofa having a cushion made of synthetic resin foam or rubber foam as a core material, comprising a seat portion and a backrest portion, Near the back of the backrest,
A sofa, characterized in that a reinforcing plate is inserted and adhered and integrated into a slit which opens to the lower surface of a core material and extends to both side surfaces of the core material. Further, the invention according to claim 2 is a sofa using a synthetic resin foam or rubber foam having cushioning properties as a core material, comprising a seat portion and a backrest portion, and a reinforcing plate adhered integrally to the back surface of the backrest portion. Become
Further, the sofa is characterized in that a synthetic resin foam having a cushioning property or a rubber foam material is bonded and integrated to the back surface of the reinforcing plate. According to a third aspect of the present invention, there is provided the sofa according to the first or second aspect, wherein the reinforcing plate is cardboard or corrugated paper. In addition, the invention according to claim 4 cuts a sofa core material having a seat portion and a backrest portion from a synthetic resin foam having a cushioning property or a rubber foam block with a cutter, and also, on the backrest portion, on both side surfaces of the core material. A method of manufacturing a sofa, comprising cutting a slit that opens to the lower surface of a core material, inserting a reinforcing material into the formed slit, and bonding and integrating the slit into a sofa core material.

[0009]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a first embodiment of the present invention. The sofa core material (1) is made of a synthetic resin foam or rubber foam having cushioning properties, and includes a seat portion (3) for a person to sit on and a backrest portion (2) for applying a load on the back. Seat (3)
The backrest portion (2) may be integrally formed of the same synthetic resin foam or rubber foam, but may be formed by combining different synthetic resin foams or rubber foams having different hardnesses to form the sofa core material. Seat (3)
Further, another synthetic resin foam or rubber foam may be partially used for the backrest (2). For example, the backrest (2) is made of a soft urethane foam having a relatively high hardness, and the seat (3) is made of a soft urethane foam having a lower hardness and a superior cushioning property than the backrest (2), or a backrest. (2) and the seat portion (3) are integrally formed of a soft urethane foam having relatively high hardness, and the surface of the seating surface of the seat portion (3) is covered with rubber foam having relatively low hardness and excellent cushioning properties. It can also be done.

A slit (8) is formed inward from the back (7) of the backrest (2) to reach both sides (6) and (6 ') of the core material and open to the lower surface (4) of the core material. , The reinforcing plate (5) is inserted into the slit (8), and is bonded and integrated with the core material.

The synthetic resin foam or the rubber foam is
Any material having an appropriate cushioning property may be used, and a flexible polyurethane foam, a semi-rigid polyurethane foam, a flexible polyethylene foam, a mechanical foam formed from rubber latex, or the like can be used. As the rubber, any commonly used rubber such as natural rubber, chloroprene rubber, SBR and NBR can be used. As the reinforcing plate (5), a plywood, a metal plate, a synthetic resin plate such as a polypropylene sheet, corrugated paper, cardboard, etc. can be used, but in consideration of cost, workability and recyclability, corrugated paper and cardboard are excellent. Corrugated cardboard and cardboard are also superior in that the use of an adhesive improves the strength of paper alone compared to the strength of paper alone. Corrugated paper or cardboard having a thickness of about 1 to 10 mm can be used, preferably 1.5 to 8 mm, more preferably 2 to 10 mm.
The thickness is about 7 mm.

The position where the reinforcing plate (5) is inserted into the backrest (2) may be a back surface (7) of the backrest (2).
From 20 mm to 50 mm. If the portion is smaller than 20 mm, the reinforcing effect due to the supporting force of the synthetic resin foam or rubber foam bonded and integrated on the back side of the reinforcing plate (5) is small, and if the portion is larger than 50 mm, the reinforcing plate ( The supporting force of the reinforcing plate (5) for the synthetic resin foam or the rubber foam material located on the back surface of 5) is reduced, and the synthetic resin foam or the rubber foam material is easily damaged. It is preferable that the upper end of the reinforcing plate is located 10 to 200 mm below the upper end of the backrest. When the upper end of the reinforcing plate is located within 10 mm from the upper end of the backrest, the hardness of the reinforcing plate is directly transmitted to the hand when the hand is placed on the upper end of the backrest, and the synthetic resin located at the top of the reinforcing plate Foams and rubber foams tend to be easily damaged. In addition, when the upper end of the reinforcing plate is present at a position 200 mm or more from the upper end of the backrest, a load is applied to the boundary between the synthetic resin foam between the upper end of the reinforcing plate and the backrest when supporting the weight of a person sitting on the upper part of the backrest. And the backrest of the core material may be damaged at this point.

FIG. 2 shows a second embodiment of the present invention. The sofa core material (1) is made of cushioning synthetic resin foam or rubber foam, and is composed of a seat portion (3) for a person to sit on and a backrest portion (2) for seating and applying a load on the back. A reinforcing plate (2) is adhesively bonded to the back surface of the backrest (2), and a cushioning synthetic resin foam or rubber foam material (14) is bonded and integrated to the back surface of the reinforcing plate (5). Things. A synthetic resin foam or rubber foam material (1) having a cushioning property and adhered to the back surface of the reinforcing plate (5)
4) may be the same as the synthetic resin foam or the rubber foam material forming the seat portion (3) or the backrest portion (2) of the sofa core material (1), or another material may be used. The synthetic resin foam or rubber foam material (5) having a cushioning property, which is adhesively bonded to the back surface of the reinforcing plate, has a thickness of 20%.
If the thickness is smaller than 20 mm, the supporting force of the reinforcing plate (5) by the synthetic resin foam or the rubber foam material (14) is insufficient, and the reinforcing effect is small.
When the thickness is larger than 0 mm, the supporting force of the reinforcing plate (5) against the synthetic resin foam or the rubber foam material (14) adhered to the back surface of the reinforcing plate (5) is reduced, and the synthetic resin foam or the rubber foam material (14) becomes It is easy to be damaged. It is preferable that the position of the upper end of the reinforcing plate is also in the same range as in the first embodiment.

FIG. 3 illustrates the invention according to claim 4. From a cushion (synthetic resin foam or rubber foam block (not shown) having the same length as the sofa core material (1) to be molded), a cutter (3) to a backrest (2), a back surface (7),
When the sofa core material (1) is obtained by cutting along the shape of the core material lower surface (4), the back surface (7) of the backrest (2)
A slit (8) is simultaneously cut from the lower surface (4) of the core material to the inside of the backrest (2). Reinforcing plate (5) with adhesive applied inside formed slit (8)
Is inserted and bonded and integrated with the synthetic resin foam or rubber foam material of the backrest (2) to obtain a sofa core material.

In the present invention, the obtained sofa core material (1)
Is covered with an upholstery (not shown) to form a sofa. As a covering material, besides cloth material and leather material,
Use all commonly used materials, such as a combination of different materials, and a padding material such as soft urethane foam or solid cotton on the core material side to improve cushioning. You can do it.

Although the embodiment of the present invention is as described above, the present invention is not limited to this embodiment. For example, a sofa with an armrest on the seat (3), a lower surface (4) of the seat, etc. The present invention is also applied to a sofa with legs, a sofa with a thin seat portion (3), and is not affected by differences in sofa shape.

[0017]

As described above, the present invention uses a high-density and hard synthetic resin foam or a rubber foam as a core material in order to increase strength, impair cushioning properties,
Synthetic resin foam that does not increase cost and uses a strong reinforcing frame such as a steel pipe as a reinforcing material, does not increase weight and costs, and has moderate cushioning as a sofa Or even if you use rubber foam as a sofa core,
Since a low-cost reinforcing structure is made possible, a sofa having sufficient strength for practical use and good cushioning properties can be obtained at low cost.

According to the first aspect of the present invention, the reinforcing plate is formed in the vicinity of the back surface of the backrest by opening the lower surface of the core material and inserting and reinforcing the reinforcing plate into the slit extending to both side surfaces of the core material. In combination with the adhesive structure, the strength is higher than the strength of the reinforcing plate alone, and even a lightweight reinforcing plate can provide sufficient practical reinforcing effect, such as damage to the back cushioning material and sag of the seat cushioning material There is also an effect of prevention.

According to the second aspect of the present invention, even if a sofa core material is not provided with any reinforcing structure, a reinforcing plate is bonded to the back surface of the backrest portion of the sofa core material, and the cushioning synthetic resin is further provided. The effect similar to that of the sofa according to the first aspect of the present invention can be obtained by a process of simply bonding and integrating a foam or a rubber foam material.

According to the third aspect of the present invention, even if the reinforcing plate is inexpensive and lightweight corrugated cardboard or cardboard, both sides of the reinforcing plate are firmly adhered and integrated with the cushioning material of the sofa core material. A reinforcing effect higher than a single strength can be obtained, and a sofa having practically sufficient use strength can be obtained at low cost.

According to the fourth aspect of the present invention, the synthetic resin foam or the rubber foam block having the cushioning property is used for the second step.
When cutting a sofa core material having a seat and a backrest with a three-dimensional cutter, the slit into which the reinforcing plate is to be inserted can be cut at the same time, so there is no need to post-process the back surface of the sofa core material. It is a target.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of a sofa core material of the present invention.

FIG. 2 is a perspective view showing one embodiment of a sofa core material of the present invention.

FIG. 3 is an explanatory view showing one embodiment of a method for manufacturing a sofa core material of the present invention.

FIG. 4 is an explanatory view showing a conventional sofa core material provided with a reinforcing plate.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 sofa core material 2 backrest portion 3 seat portion 4 core material lower surface 5 reinforcing plate 6 core material side surface 6 ′ core material side surface 7 back surface 8 slit

Claims (4)

[Claims] 1. A sofa having a cushion made of a synthetic resin foam or a rubber foam as a core material, comprising a seat portion and a backrest portion, and near a back surface of the backrest portion,
A sofa which is formed by inserting a reinforcing plate into a slit which opens to the lower surface of a core material and which extends to both side surfaces of the core material and is integrated with the slit. 2. A sofa using a cushioning synthetic resin foam or a rubber foam as a core material, comprising a seat portion and a backrest portion, wherein a reinforcing plate is bonded and integrated to the back surface of the backrest portion, and further reinforced. A sofa characterized in that a synthetic resin foam having a cushioning property or a rubber foam material is bonded and integrated to a back surface of a board. 3. The sofa according to claim 1, wherein the reinforcing plate is cardboard or corrugated cardboard. 4. A sofa core material having a seat portion and a backrest portion is cut from a synthetic resin foam or a rubber foam block having a cushioning property by a cutter, and the backrest portion reaches both side surfaces of the core material and a lower surface of the core material. A method for manufacturing a sofa, comprising: cutting a slit that opens into a slit; inserting a reinforcing material into the formed slit;