JP2799277B2 - Mattress device and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mattress device formed by laminating a padding on a spring unit, and covering the laminated body with an exterior body, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In general, a mattress device has a spring unit formed by connecting a large number of coil springs in a matrix, and a padding such as synthetic cotton or urethane foam is laminated on the spring unit. . This laminate is covered with an exterior body formed of a mirror portion and a town portion.

In the mattress device having such a configuration, the padding is connected and fixed to the spring unit with a large number of clips in order to prevent the padding from moving relative to the spring unit. Further, in order to prevent the exterior body from moving relative to the spring unit, one end is connected and fixed to the inner surface of the mirror unit to provide a flange cloth, and the other end of the flange cloth is provided around the spring unit. Like the padding, the clip is connected and fixed.

According to such a configuration, the padding is prevented from being displaced by the clip and the flange cloth, and the exterior body is prevented from being displaced by the flange cloth.

[0005] However, the operation of connecting the padding to the spring unit with a large number of clips requires a great deal of time and labor, which may lead to a decrease in productivity. In addition, the flange cloth is connected by the spring unit. That work also takes a lot of trouble.

On the other hand, in the case where the mattress device has been damaged due to long-term use and must be discarded, recently, the waste cannot be collected unless it is discarded for each type of material. In many areas, collection systems are used. When the mattress device is discarded in an area where the sorting and collection is being performed, the spring unit, which is a metal part, and the padding and the outer casing made of synthetic fiber or the like must be discarded separately.

In this case, if the padding is connected to the spring unit by a large number of clips, it is not easy to remove the padding from the spring unit, and similarly, it is not easy to remove the outer package from the spring unit. Therefore, the disassembly work at the time of disposal may take a lot of trouble.

[0008]

As described above, in the conventional mattress device, the padding is connected to the spring unit with a large number of clips, and the exterior body is also connected to the spring unit with a clip via the flange cloth. In some cases, the assembling operation takes a lot of time, and when it is necessary to disassemble each material at the time of disposal, the assembling operation takes time.

The present invention has been made in view of the above circumstances, and an object of the present invention is to allow a padding and an outer package to be held and fixed to a spring unit without using a large number of clips, and to be easily disassembled. And a method for manufacturing the same.

[0010]

According to the present invention, there is provided a mattress device comprising: a spring unit having an upper surface and a lower surface;
An outer package having a padding stacked on the upper and lower surfaces of the spring unit, a mirror portion covering the upper and lower surfaces of the stacked body of the padding and the spring unit, and a town portion covering the outer peripheral surface, respectively; A pair of upper and lower flange cloths provided with one end connected to the inner peripheral portion of the
A connecting member formed of a heat-shrinkable synthetic resin and connected to the other end portions of the pair of upper and lower flange cloths on the outer peripheral surface of the spring unit and provided with a tension to the flange cloth by being heated and contracted; It is characterized by having.

[0011] In the method of manufacturing a mattress device according to the present invention, a laminated body in which a filling is laminated on upper and lower surfaces of a spring unit is covered with an exterior body comprising a mirror portion covering the filling and a gusset covering the outer peripheral surface of the spring unit. In a method of manufacturing a mattress device comprising: a step of laminating the padding on the upper and lower surfaces of the spring unit; and a pair of mirror portions having one end of a flange cloth connected to an inner peripheral portion on the upper and lower surfaces of the spring unit. A step of stacking, a step of connecting the other end of the pair of upper and lower flange cloths with a connecting member made of a heat-shrinkable synthetic resin on the outer peripheral surface of the spring unit, and shrinking the heating by heating the connecting member. Applying a tension to the flange cloth.

[0012]

According to the above construction, tension can be applied to the flange cloth by heating and contracting the connecting member connected to the other ends of the pair of upper and lower flange cloths during assembly.
The padding and the package can be fixed to the spring unit via the flange cloth, and the package and the package can be separated from the spring unit only by cutting and removing the connecting member during disassembly.

[0013]

Embodiments of the present invention will be described below with reference to the drawings.

FIGS. 1 to 3 show a first embodiment of the present invention. The mattress device shown in FIG. The spring unit 1 is formed by arranging a large number of coil springs 2 in a matrix and connecting upper and lower end surfaces of adjacent coil springs 2 with a helical wire 3. A frame line 4 is connected to upper and lower peripheral edges of the spring unit 1 by clips (not shown).

On the upper and lower surfaces of the spring unit 1, paddings 6 each formed in a rectangular shape slightly larger than the upper and lower surfaces of the spring unit 1 are stacked and stacked via a sheet-like protective material 5 such as felt. Is placed. The filling 6 is formed by compressing synthetic fiber into a layer having a predetermined thickness.

The laminate of the spring unit 1 and the padding 6 is covered with an outer package 7. The exterior body 7 includes an upper mirror section 8 and a lower mirror section 9 which are respectively laminated on the upper and lower surfaces of the spring unit 1, and a gusset section 10 covering the outer peripheral surface. The mirror portions 8, 9 and the town portion 10 are respectively composed of outer materials 8a, 9a, 10a and linings 8b, 9
b, 10b between the sheet-like urethane foam 8c,
9c and 10c are provided, and the three members are integrally quilted. The upper and lower ends of the gusset 10 are integrally sewn to the periphery of the upper mirror 8 and the lower mirror 9 by a tape 11.

The linings 8b and 9b of the mirrors 8 and 9 have
One end in the width direction of the flange cloth 12 is sewn over the entire periphery of the peripheral portion, and the other end covers the outer peripheral surface of the padding 6 as shown in FIG. A pair of upper and lower flange cloths 12
On the outer surface of the other end, a relatively soft heat-shrinkable synthetic resin tape is formed in a loop shape in the middle of the spring unit 1 in the height direction. Direction) Both ends are connected. Connecting member 1
Means for connecting the flange 3 to the flange cloth 12 include sewing, bonding using an adhesive, or bonding with a clip. In this embodiment, the fixing is performed by sewing.

As the relatively soft heat-shrinkable resin forming the connecting member 13, vinyl chloride resin, EPT, P
ETP, cross-linked polyethylene, silicone rubber, and the like are used, and a phenomenon is attempted in which these resins are heat-molded, and the molded product is reheated to return to its original shape.

Therefore, when the connecting member 13 is heated, the loop shape of the connecting member 13 and the width of the spring unit 1 along the vertical direction are reduced.
The contraction applies tension to the other end of the flange cloth 12. Thereby, the periphery of the padding 6 is wrapped by the flange cloth 12 and held and fixed to the spring unit 1. At the same time, each of the mirror parts 8 and 9 connected to one end of the flange cloth 12 also
2 and is fixed to the spring unit 1.

After the connecting member 13 is thermally shrunk, the upper and lower ends of the gusset 10 of the exterior body 7 are formed around the mirrors 8 and 9 by the tape 12 as described above. Sewn on.

FIGS. 3A to 3D show the steps of manufacturing the mattress device having the above-described structure. FIG. 3A shows a first step. In the first step, the padding 6 is laminated on the upper and lower surfaces of the spring unit 1 via the protective material 5. FIG. 3 (b)
In the second step shown in FIG. 5, one end of the flange cloth 12 is sewn to the periphery of the inner surfaces of the upper and lower mirror sections 8 and 9 of the exterior body 7, and further connected to the other end of the flange cloth 12 of the upper mirror section 8. One end in the width direction of the member 13 is joined.

In a third step shown in FIG. 3C, the upper and lower mirror portions 8 and 9 provided with the flange cloth 12 and the connecting member 13 in the second step are stacked and mounted on the filling 6 respectively. As a result, the other end of the flange cloth 12 having one end sewn to the periphery of the inner surface of each of the mirror sections 8 and 9 covers the outer peripheral surface of the padding 6. Next, the other end in the width direction of the connecting member 13 is connected and fixed to the other end of the flange cloth 12 provided on the lower mirror portion 9. FIG. 2 shows a state in which the connecting member 13 is connected and fixed to the pair of upper and lower flange cloths 12.

As described above, if the padding 6 and the mirror portions 8 and 9 are laminated on the upper and lower surfaces of the spring unit 1, the fourth
As shown in FIG. 3D, the stacked body of the spring unit 1, the filling 6, and the upper and lower mirror parts 8 and 9 is carried into the hot air heating furnace 22 by the conveyor 21.

The temperature of the hot air in the heating furnace 22 is controlled by the connecting member 1.
3 is a temperature at which heat shrinkage of 3 can be performed,
When the connecting member 13 is heated together with the laminate at the temperature of 30 ° C. and shrinks in the diameter reducing direction, the other end of the flange cloth 12 is pulled inward of the spring unit 1. That is, tension is applied to the flange cloth 12. When the other end of the flange cloth 12 is pulled, the padding 6 wrapped around by the flange cloth 12 is held and fixed to the spring unit 1 and the flange cloth 1
The mirrors 8 and 9 to which one end of the mirror 2 is connected are also fixed to the spring unit 1.

When the size of the loop formed by the connecting member 13 is adjusted and thermally shrunk, not only is the tension applied to the flange cloth 12 but also the flange cloth 12 is pressed against the outer peripheral surface of the spring unit 1. If integrated with the unit 1, the padding 6 and the exterior body 7 can be more securely fixed to the spring unit 1.

In the fifth step, the outer peripheral surface of the spring unit 1 of the stacked body unloaded from the heating furnace 22 is covered with the gusset 10, and the upper and lower ends of the gusset 10 are connected to the upper mirror section 8. By suturing the periphery of the lower mirror section 9 with a tape 11, the mattress device shown in FIG. 1 is manufactured.

According to the mattress device manufactured in this manner, the paddings 6 and the mirror portions 8 and 9 stacked on the upper and lower surfaces of the spring unit 1 are provided with one end portions connected to the mirror portions 8 and 9. The other end of the pair of upper and lower flange cloths 12 is pulled by the connecting member 13 and is fixed to the spring unit 1 via the flange cloths 12. That is, the filler 6 and the exterior body 7 are fixed to the spring unit 1 by applying heat to the flange cloth 12 by contracting the connecting member 13 by heat.

Therefore, the padding 6 and the mirror parts 8 and 9 stacked on the spring unit 1 do not have to be connected to the spring unit 1 by using many clips as in the prior art, and the connecting member 13 is thermally contracted. Can be connected and fixed to the spring unit 1 alone, so that the operation of connecting and fixing the padding 6 and the mirror portions 8 and 9 to the spring unit 1 can be easily and quickly automated without manual work. It can be carried out.

On the other hand, when the spring unit 1 is separated from the padding 6 and the exterior body 7 in order to discard the mattress device having the above-described structure, the tape 11 having the gusset 10 connected to the mirrors 8 and 9 should be used. After removing the gusset 10 from the outer peripheral surface of the spring unit 1, the connecting member 13 in a contracted state on the outer peripheral surface of the spring unit 1 is cut along a circumferential direction by, for example, a cutter. Thereby, the tension given by the connecting member 13 is removed from the flange cloth 12.

As described above, when the tension of the flange cloth 12 is removed, the holding and fixing state of the padding 6 and the mirror portions 8 and 9 are released, so that the padding 6 and the mirror portions 8 and 9 are released from the spring unit 1. Can be separated.
That is, at the time of disposal, the padding 6 and the outer package 7 can be separated from the spring unit 1 by a relatively easy operation of cutting the connecting member 13 formed of a tape-shaped synthetic resin.

FIG. 4 shows a second embodiment of the present invention. In this embodiment, the protective material 5 and the padding 6 laminated on the upper and lower surfaces of the spring unit 1 are partially adhered by a hot melt 31 as an adhesive, that is, in a state where they can be easily separated.

According to such a configuration, it is possible to prevent the protective member 5 and the padding 6 laminated on the spring unit 1 from shifting during the assembly until the connecting member 13 is thermally contracted. As a result, assembling accuracy can be improved.

FIG. 5 shows a third embodiment of the present invention. In this embodiment, a thread-like member 32 is used to fix the protective material 5 and the padding 6 laminated on the upper and lower surfaces of the spring unit 1 to the spring unit 1. That is, the spring unit 1, the protective material 5 and the padding 6
The protective member 5 and the stuffing 6 are fixed to the spring unit 1 by passing the thread-like member 32 through the laminate and connecting the buttons 33 to both ends of the stuffing 6 respectively. is there.

FIG. 6 shows a fourth embodiment of the present invention. In the fourth embodiment, the upper mirror 8 'of the exterior body 7' and the
In the case of manufacturing a mattress device having such a configuration, the connecting member 13 is contracted, and then the lower end portion of the gusset 10 and the peripheral portion of the lower mirror portion 9 are formed. Only need to be sewn with tape 11.

The flange cloth provided on the peripheral portion of the inner surface of the mirror portion may be provided continuously over the entire periphery of the peripheral portion, or may be provided partially. It does not matter.

In each of the above embodiments, the connecting member is a
It is formed in the shape of a tape and is provided over the entire length of the outer peripheral surface of the spring unit. May be partially connected to each other. When the flange cloth is partially provided on the outer peripheral surface of the spring unit, some of the flange cloths may be connected by the tape-shaped connecting member.

According to such a configuration, the length of the connecting member is contracted by heating, and the tension is applied to the flange cloth, so that the padding and the exterior body are separated from each other by the first member.
In the same manner as in the embodiment, it can be fixed to the spring unit.

[0038]

As described above, according to the present invention, one end of a flange cloth is connected to the periphery of the inner surface of the upper mirror part and the lower mirror part constituting the exterior body. A connecting member made of a heat-shrinkable synthetic resin is connected, and tension is applied to the flange cloth by heating and shrinking the connecting member,
Thereby, the padding and the exterior body are fixed to the spring unit.

Therefore, the padding and the outer package are fixed to the spring unit via the flange cloth by the contracting force of the connecting member, so that it is not necessary to use a large number of clips as in the prior art, and the connecting operation is not required. It can be easier and faster. In addition, since the operation of thermally shrinking the connecting member can be easily automated, the productivity can be improved by this.

Further, when disposing the mattress device having the above-described structure in an area where sorting and collection are performed, the exterior member and the padding can be separated from the spring unit by cutting the connecting member made of synthetic resin. Therefore, it is possible to easily perform the operation of separating the components constituting the mattress device for each material.

[Brief description of the drawings]

FIG. 1 is a sectional view of a part of a mattress device according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of a state before the town part of the exterior body is attached.

FIG. 3 is an explanatory view of a manufacturing process of the mattress device.

FIG. 4 is a cross-sectional view of a part of a mattress device according to a second embodiment of the present invention.

FIG. 5 is a cross-sectional view of a part of a mattress device according to a third embodiment of the present invention.

FIG. 6 is a cross-sectional view of a part of a mattress device according to a fourth embodiment of the present invention.

[Description of Signs] 1 ... Spring unit, 6 ... Filling, 7 ... Outer body,
8, 9 mirror part, 10 town part, 12 flange cloth, 13
... Connecting member.

Claims (2)

(57) [Claims] 1. A spring unit having an upper surface and a lower surface, a padding laminated on the upper surface and a lower surface of the spring unit, a mirror portion and an outer peripheral surface respectively covering upper and lower surfaces of a laminated body of the padding and the spring unit. An exterior body having a covering portion, a pair of upper and lower flange cloths provided with one end connected to an inner peripheral portion of each of the mirror portions, and an outer peripheral surface of the spring unit formed of a heat-shrinkable synthetic resin The mattress device according to claim 1, further comprising a connecting member provided to be connected to the other end portions of the pair of upper and lower flange cloths, the connection member being heated and contracted to apply tension to the flange cloth. 2. A mattress device is manufactured in which a laminate in which stuffing is laminated on upper and lower surfaces of a spring unit is covered with an exterior body comprising a mirror portion covering the stuffing and a gusset covering the outer peripheral surface of the spring unit. A method of laminating the padding on the upper and lower surfaces of the spring unit, laminating a pair of mirror parts having one end of a flange cloth connected to an inner peripheral portion thereof on the upper and lower surfaces of the spring unit, A step of connecting the other end of the pair of upper and lower flange cloths with a connection member made of a heat-shrinkable synthetic resin on the outer peripheral surface of the unit, and applying heat to the connection member to cause the flange cloth to contract and apply tension to the flange cloth And a process for producing a mattress device.