JP2003290578A - Cotton stuffed body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a repulsive cotton stuffed body such as a mattress capable of imparting functions such as water absorptivity, moisture absorptivity, a moisture discharging property, divergence, a warmth retaining property and a light weight property without the feeling of sinking to the floor. <P>SOLUTION: For the stuffed body, cotton (6) is stuffed inside a plurality of the sections of side cloth divided into a plurality of the sections by forming one or more inner partitions (4, 5) in a longitudinal direction or a lateral direction. At least one selected from the inner partition (5) and the side face (3) of the side cloth is formed of an elastic tape and the cotton (6) is formed of compressed cotton in a plurality of the layers of different compressibilities. The plurality of the layers of the different compressibilities are integrally molded in the order of a hard cotton layer, a body pressure distributing soft layer and a body function layer from the bottom. It is preferable that the Asker F hardness of the hard cotton layer is ≥30 and ≤50, the Asker F hardness of the body pressure distributing soft layer is ≥10 and ≤20, and the Asker F hardness of the body contact function layer is >20 and <30. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a padded object useful as a mattress, a bed pad, a mattress, a kotatsu mattress, a cushion, a pillow, and the like.

[0002]

2. Description of the Related Art Conventionally, stuffed objects such as mattresses, bed pads, mattresses, kotatsu mattresses, cushions and pillows have been formed into a predetermined shape after opening raw cotton such as cotton or synthetic fiber with a card machine to form a fiber web. It was manufactured by folding it into a batting body, filling the batting body from the opening of the side ground into the side ground, and sewing the side ground opening. However, the conventional stuffed object has a large amount of cotton to fill and is heavy and has a feeling of flooring (it sinks due to the weight of the human body when actually worn). There was a problem that I could not wash in this condition. In order to improve this, a method has been proposed in which opened short fibers are blown while being molded into the side ground using pressure air, after which the side ground opening is closed and then sewn in the thickness direction together with the side ground. (JP-A-11-290160). Further, as another method, it has been proposed to use solid cotton fused with low-melting point fibers as a stuffing (Japanese Patent Laid-Open No.
137857, 6-245850, 11-342280).

In particular, in the case of a padded object in a mattress, the following problems have been encountered when trying to construct a thick padding. (1) It was necessary to prepare at least 2-3 laminated battings in advance. (2) It was necessary to quilt the side fabric containing the batting to prevent it from slipping and causing cotton slippage. (3) Quilting (stitching) requires a sewing machine exclusively for thick materials, has a space for introduction, and the cost of capital investment was high. (4) Binding machine has a thickness of 50 mm at 2.25 kg / m ^2.
However, it was technically impossible to bind the batting with the maximum thickness. (5) The filling material made by the conventional method has a problem that it is easily worn out and cannot withstand long-term use.

[0004]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned problems of the prior art by providing elasticity and no feeling of flooring.
It is an object of the present invention to provide a batting object that can be provided with functionality such as water absorbency, hygroscopicity, moisture release, wicking properties, heat retention, and lightness.

[0005]

In order to achieve the above-mentioned object, the batting object of the present invention is characterized in that the side material is divided into a plurality of rooms by forming one or more partitions in the longitudinal direction or the lateral direction. A stuffed object filled with batting in multiple rooms,
At least one selected from the side wall of the partition and the side material is formed of an elastic tape, and the batting is formed of a plurality of layers of compressed cotton having different compressibility in the thickness direction.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, batting is stuffed in the plurality of chambers on the side ground which is divided into a plurality of chambers by forming one or more partitions in the longitudinal direction or the lateral direction. , The batting is hard to move, and it is hard to get tired. Also, since there is no binding part that penetrates in the thickness direction, there is surface smoothness,
Moreover, there is an advantage that there is little damage on the side ground.

Next, at least one selected from the side wall of the partition and the side material is formed of a stretchable tape. As a result, when the human being is in use, a force that pops out the batting in the horizontal direction works, but when not in use, a force that pushes the batting back to the original state works, making it less likely to set. In addition, since the lateral material can be stretched when the batting is filled into the lateral material, the material can be efficiently filled.

Next, the batting is formed of a plurality of layers of compressed cotton having different compressibility in the thickness direction. This makes it possible to separate the layer for eliminating the feeling of flooring, the body pressure dispersion layer, and the functional layer adapted to the human body when touching the skin by different layers.

It is preferable that the elastic tape is bonded to the side material forming the front surface and the back surface while being stretched in the width direction. Specifically, it can be realized by making the thickness of the batting larger than the width of the elastic tape. This is because when the stretchable tape is pulled in the width direction, the breathability of the stretchable tape is increased, and moisture generated by the human body and absorbed by the batting easily diffuses to the outside. In the above, the air permeability in the steady state of the elastic tape is JIS L-
1018 100 cm ³ / cm ³ · s by the measuring method specified in 8.33.1
It is preferably more than 200 cm ³ / cm ³ · s
The above is preferable.

The stretchable tape in the width direction preferably has a tensile elongation ratio of 3 to 70%, more preferably 20 to 5%.
0% is preferable. Within this range, the air permeability will be further increased, and the moisture will be easily diffused.

Further, it is preferable that the plurality of layers of compressed cotton having different compressibility be integrally molded by thermal compression.
If integrally molded, the entire shape will not easily lose its shape, and it can withstand long-term use.

Further, it is preferable that the plurality of layers of compressed cotton having different compressibility are laminated in the order of a solid cotton layer, a body pressure-dispersing flexible layer, and a body function layer. The cotton wool layer has a non-floor feeling and is elastic, and the body pressure distribution flexible layer has the most flexible and function of dispersing body pressure. The body function layer absorbs human body's sweat and warmth. Has the function of giving. In terms of hardness, the Asker F hardness of the solid cotton layer is 3
0 or more and 50 or less, the Asker F hardness of the body pressure dispersion flexible layer is 1
0 or more and 20 or less, Asker F hardness of the body contact functional layer is 2
It is preferably more than 0 and less than 30.

It is preferable that the cotton wool layer and the body pressure-dispersing flexible layer are formed of polyester fibers mixed with adhesive fibers, and the human body functional layer is formed of natural fibers. Examples of the natural fiber include wool (wool) and cotton. In addition, the human body functional layer may be a synthetic fiber,
For example, when polyester fibers mixed with ceramic powder are used, they have an exothermic property, which is effective for a person who cannot easily release the heat of the human body and is cold.

The plurality of layers of compressed cotton having different compressibility may have a structure in which a solid cotton layer is present in the center and sheet-like multilayer structures are laminated on both surface layers. With such a structure, both the front and back sides can be used alternately.

The padded object in the present invention is a mattress, bed pad, mattress, kotatsu mattress, cushion,
It can be applied to at least one selected from a cushion, a cushion, and a pillow. It is especially suitable for mattresses.

Next, description will be made with reference to the drawings. FIG. 1 is a perspective view of a mattress according to an embodiment of the present invention. This mattress 1 has two partitions 4 in the vertical direction and 3 in the vertical direction.
The side material 2 divided into two rooms is filled with batting, and the inner partition 4 and the side surface 3 of the lateral material are formed of elastic tape. Since the inner partition 4 divides the room into three rooms, and batting is filled in the three rooms, the batting does not easily move and the structure does not easily set. Further, it is possible to fill the middle room where the pressure of the human body is most applied with dense batting or to fill a large amount of batting. Furthermore, since there is no binding part that penetrates in the thickness direction, it has surface smoothness and less damage to the side ground.

Further, since the inner partition 4 and the side surface 3 of the side surface are formed of an elastic tape, a force for the batting of the batting to work in the horizontal direction works when in use, but when not in use, The force that pushes back to the state of works, and it is hard to get tired.

Next, FIG. 3 is a perspective view showing the internal structure of the end portion of the mattress 1. The ends are formed so that they can be opened and closed with a fastener 7 so that the inside can be observed. When the fastener 7 is opened and the upper end 8 of the side material 2 is lifted up, the elastic tape 5 of the partition 4 is pulled and can be opened. In order to fill the batting 6 into the side material 2, the upper end portion 8 of the side material 2 and the end portion 9 of the side surface 3 are opened and the filling is performed from this portion.

FIG. 4 is a perspective view of the side ground 2. The side surface 3 of the side material 2 is formed of an elastic tape, and two partition walls 4 and 5 of the elastic tape are formed in the longitudinal direction.

Next, FIG. 5 shows a cross-sectional view of batting according to an embodiment of the present invention, in which a solid cotton layer 11, a body pressure dispersion flexible layer 12, and a body function layer 13 are laminated in this order from the bottom and integrally formed. Compressed cotton 14. This compressed cotton 14 is manufactured as shown in FIG. The short conveyor card webs 21, 22 and 23 having different mixing ratios of low melting point binder fibers are connected to the lower conveyor 24.
Then, it is sent to the left side while being compressed by the pressing lattice, and is passed through the lower conveyor 25 and the upper conveyor 27 in the heating chamber 28 to be integrally molded by heating and compression. The heating temperature is, for example, 140 to 150 ° C., and the heating time is 150 seconds.

The mattress 1 thus obtained is shown in FIG.
As shown in, from the bottom, a cotton layer 11, a body pressure dispersion flexible layer 12,
The body function layers 13 are laminated in this order and integrally formed, and are elastic, have no floor feeling, are flat, but are always inflated and hard to get tired, and are functionally excellent as a health mattress. It was In addition, water absorption, hygroscopicity, heat retention,
Functionality such as lightness can be added.

Next, FIG. 8 is a cross-sectional view of batting according to another embodiment, which has a structure in which a solid cotton layer 32 is present in the center and sheet-like multilayer structures 31, 31 are laminated on both surface layers. With such a structure, both the front and back sides can be used alternately.

[0023]

EXAMPLES Next, the present invention will be described more specifically with reference to examples.

(Example 1) (1) Formation of side fabric As shown in FIG. 4, the front side fabric 2 and the back side fabric are made of cotton woven fabric used in a usual mattress, and the partition 5 and the side face 3 of the side fabric are used. Was a stretchable tape of 100% polyester knit. Stretchable tape is a "grab method" using a constant-speed stretch-type tensile tester with a self-recording device according to the stretch elastic modulus measurement method of knitted fabrics specified in JIS L108 8 15.2B method.
Measured by. The size of the test piece is 10 cm in width and 15 c in length
m, gripping interval 76 mm, pulling speed 10 cm / min, constant load 7.4 N, and number of repetitions 10 times, the elongation was 40% or more and the elongation elastic modulus was 97% or more. Also,
The elastic tape is breathable as defined in JIS L108 8 33.1 method was 210.7cm ³ / cm ³ · S. The elastic tape had a width of 70 mm including a seam with the side fabric, and a width from the seam to the seam of 50 mm.

The size of the side ground was a single size, 200 cm in length and 100 cm in width, and two partitioning pieces were evenly placed along the vertical direction. (2) Formation of batting As the low melting point binder fiber, a core-sheath type polyester low melting point fiber (fineness 4.4 denier, fiber length 51 mm) manufactured by Toray Industries, Inc. was used. Normal polyester (polyethylene terephthalate) fiber has a fineness of 7 to 18 denier and a fiber length of 64 mm.
Was used.

The laminated cotton is manufactured by using the apparatus shown in FIG.
Compression integral molding was performed at 150 ° C. for a heating time of 150 seconds. The total thickness was 80 mm.

The surface hardness of each layer was calculated by averaging the values measured at three points using an Asker F type hardness meter manufactured by Kobunshi Keiki Co., Ltd. The higher this value is, the harder it is. The contents of the batting are shown in Table 1 below.

[0028]

[Table 1]

(3) Formation of mattress The compression-integrated batting formed as described above (length 20)
0 cm, width 40 cm in the center, 30 cm at both ends, thickness 8
0 mm) was filled into the side ground through the opening of the fastener 7 shown in FIG. 3 to prepare the mattress shown in FIG. The stretch tape had a width from the seam to the seam of 50 mm, whereas the mattress had a thickness of 80 mm, and the stretch tape was pulled in the width direction.

The obtained mattress was elastic, had no feeling of flooring, and had good sleeping comfort. The shape was flat, and it was always inflated and hard to settle, and it was functionally excellent as a health futon. Further, it was possible to impart functionality such as water absorption, hygroscopicity, heat retention, and lightness.

FIG. 2 is a diagram showing the condition of the set after the actual use of the mattress of FIG. 1 for 3 months. The experimenter is 1.7 m tall and weighs 65 kg. Although a slight settling was seen, there was no settling so that it could be transformed into a mattress, and the state was almost the same as the initial state. In particular, since the stretchable tape was used for the partition 4 and the side surface 3 of the side ground, it was still stretched in the vertical direction and had a good appearance.

In the above embodiment, the mattress was divided into three sections, with the center in the width direction being 40 cm and the both ends being 30 cm, but the 20 cm width was divided into 5 sections, totaling 100 cm.
Can also be In this way, the futon becomes even less prone to fatigue.

Also, there are 5 sections with a width of 20 cm (total 10
0 cm) is single size, 20 cm width is 6 sections (total 120 cm) is semi-double size, 2
The 0 cm width and 7 sections (total 140 cm) can be double size, and the 20 cm width and 8 sections (total 160 cm) can be double deluxe (king) size, which is preferable because the batting can be standardized.

(Example 2) A mattress was prepared in the same manner as in Example 1 except that the upper layer of the compression-integrated batting in Example 1 was replaced with cotton (cotton) fiber. Similar to Example 1, this mattress was also elastic, had no feeling of flooring, and had good sleeping comfort. The shape was flat, and it was always inflated and difficult to settle, and was functionally excellent as a health mattress. Further, it was possible to impart functionality of water absorption and hygroscopicity.

(Example 3) A mattress was prepared in the same manner as in Example 1 except that polyester fiber mixed with ceramic powder was used as the upper layer of the compression-integrated batting in Example 1. As the ceramic powder, a product name "Rayearth" manufactured by Farbest Co., Ltd. and sold by Nichimen Co., Ltd. was compounded in a polymer at a compounding ratio of 1% by mass, melt-spun, stretched, crimped and cut into fibers according to a conventional method. The fineness was 10 denier and the fiber length was 64 mm. Similar to Example 1, this mattress was also elastic, had no feeling of flooring, and had good sleeping comfort. The shape was flat, and it was always inflated and hard to settle, and it was functionally excellent as a health futon. Further, it has an exothermic property, and it is effective for a person who is hard to escape the heat of the human body and is cold.

Example 4 Like the laminated cotton shown in FIG.
A solid cotton layer was arranged in the center, and a padded object in which a sheet-like multilayer structure was laminated on both surface layers was prepared. The sheet-shaped cotton is cotton obtained by entwining and compressing the web carried out from the card with a needle punch. Nylon resin was previously adhered to one side of the sheet-like cotton with a hot-melt processing machine in a dot manner in advance. The black circles in FIG. 9 are dot adhesives. Four sheets were stacked with the resin side of the sheet-shaped cotton adhered by dots as the solid cotton side. When four sheets were stacked on each of the front and back sides, heat was applied again while applying pressure. At this time, the set temperature is 140 to 150 ° C. and the heating time is about 150 seconds.

By changing the kind of the sheet-shaped batting or changing the hardness of the batting, batting of a desired hardness can be achieved. Table 2 below is an example. In such a padded object, the front and back surfaces can be used alternately.

[0038]

[Table 2]

In Table 2, the sheet cotton of the surface layer is pre-compressed with a needle punch before spot-bonding with the nylon resin, and the hard cotton of the middle layer is compressed by heat at the same time as the sheet cotton of the surface layer is bonded. . In this respect, the crimping method is different from that in Table 1.

According to the embodiments of the present invention described above, the following advantages have been confirmed. (1) Since there is no binding part, it is flat and easy to roll over. It is a mattress that does not bother the elderly and bedridden people. (2) Unlike conventional stuffed objects, multiple compressed cottons with different hardnesses are laminated together, so even if a person with a heavy weight sleeps, he / she feels like wrapping gently on the surface while firmly supporting the body. I felt comfortable sleeping. (3) Due to the effect of pressure resistance dispersion and the effect of water divergence in the contraction of the gusset portion, comfortable sleep can be obtained and the number of times of rolling over, which is a physiological phenomenon, is reduced. (4) In the production method, it has been necessary to prepare a plurality of cottons in advance in order to produce a mattress with a large thickness, and to bind in the thickness direction with a heavy-duty sewing machine called a comforter machine. The present invention eliminates the need for capital investment for the binding area because the cotton does not shift.

[0041]

As described above, the mattress according to the present invention is elastic, has no feeling of flooring, is flat, and is always inflated to prevent fatigue, and is functionally excellent as a health mattress. . In addition, it is possible to impart functionality such as water absorbency, hygroscopicity, moisture releasing property, wicking property, heat retaining property and light weight.

[Brief description of drawings]

FIG. 1 is a perspective view of a mattress according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a state of a sag after actually using the mattress for 3 months.

FIG. 3 is a perspective view showing the inner surface structure of the end of the mattress.

FIG. 4 is a perspective view of the side ground of the same.

FIG. 5 is a sectional view of the same batting.

FIG. 6 is a cross-sectional view showing the same method of manufacturing batting.

FIG. 7 is a sectional view showing a wearing test of the same.

FIG. 8 is a sectional view of a batting according to another embodiment of the present invention.

FIG. 9 is a conceptual cross-sectional view of batting in another embodiment of the present invention.

[Explanation of symbols]

1 mattress 2 sides Side of 3 side ground 4,5 partition 6 batting 7 fasteners

Continued front page    F-term (reference) 3B096 AB09 AD04 BA01                 3B102 AB07 AB08 AC01

Claims (9)

[Claims] 1. A stuffed object in which batting is stuffed in the plurality of chambers of a side ground formed by forming one or more dividers in a longitudinal direction or a lateral direction and dividing the chamber into a plurality of chambers. At least one selected from the side surfaces of the side material is formed of an elastic tape, and the batting is formed of a plurality of layers of compressed cotton having different compressibility in the thickness direction. 2. The padded article according to claim 1, wherein the elastic tape is bonded to side materials forming a front surface and a back surface in a state of being stretched in the width direction. 3. The padded object according to claim 2, wherein the stretchable tape has a tensile elongation in the width direction of 3 to 70%. 4. A plurality of layers of compressed cotton having different compressibility,
The batting object according to claim 1, which is integrally molded by thermal compression. 5. A plurality of layers of compressed cotton having different compressibility,
The padded article according to claim 4, wherein a solid cotton layer, a body pressure dispersion flexible layer, and a body function layer are laminated in this order from the bottom. 6. The Asker F hardness of the solid cotton layer is 30 or more and 50 or less, the Asker F hardness of the body pressure dispersion flexible layer is 10 or more and 20 or less, and the Asker F hardness of the body contact function layer is more than 20 and less than 30. The filling material according to claim 5. 7. The solid cotton layer and the body pressure-dispersing flexible layer are formed of polyester fibers mixed with adhesive fibers, and the human body functional layer is formed of natural fibers or heat-generating fibers.
Filled object described in. 8. A plurality of layers of compressed cotton having different compressibility,
The padded article according to claim 4, wherein a solid cotton layer is laminated in the center, and sheet-like multilayer structures are laminated on both surface layers. 9. The padded object is a mattress, bed pad,
The padded object according to claim 1, which is at least one selected from a mattress, a kotatsu mattress, a cushion, a cushion, a cushion, and a pillow.