JP2802872B2 - 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.

However, the operation of connecting and fixing 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 may be attached to the spring unit. The work of linking can also take a lot of time.

On the other hand, when a mattress device is damaged due to long-term use and must be discarded, recently, waste is collected only if the material is classified and discarded. In many areas, the system is adopted. When discarding a mattress device in an area where sorting and collection are being performed, the spring unit, which is a metal part, and a padding and an outer package made of synthetic cotton or the like must be discarded separately.

[0007] In this case, if the padding is connected to the spring unit by a 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 outer body is also connected to the spring unit via the flange cloth with the clip. In some cases, the assembling work takes a lot of time, and when it is necessary to disassemble each material at the time of disposal, the disassembling work takes time.

The present invention has been made in view of the above circumstances, and has as its object the purpose of being able to hold and fix a padding and an exterior body to a spring unit without using a large number of clips, and to easily disassemble the same. 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, an upper and lower mirror portion covering the upper and lower surfaces of the laminate of the padding and the spring unit, and a gusset covering the outer peripheral surface; Both ends are connected to the inner peripheral portion of the upper and lower mirror portions, respectively, and are provided in a circumferential direction on the outer peripheral surface of the spring unit. The upper and lower mirror portions approach each other by being heated and shrunk. And a connecting member for pulling in a direction.

[0011] In the method of manufacturing a mattress device according to the present invention, the laminated body in which the padding is laminated on the upper and lower surfaces of the spring unit is covered with an exterior body comprising an upper and lower mirror portion covering the filler and a town covering the outer peripheral surface of the spring unit. In a method for manufacturing a mattress device, the step of laminating the padding on the upper and lower surfaces of the spring unit,
A step of connecting both ends of a connecting member made of a heat-shrinkable synthetic resin to peripheral portions of the inner surface on three sides excluding one side of the upper and lower mirror portions, and inserting the laminate between inner surfaces of the upper and lower mirror portions. Mounting, connecting the connecting member to the one side of the upper and lower mirror portions, and contracting the connecting member by heating the connecting members to pull the upper and lower mirror portions in a direction approaching each other. And characterized in that:

[0012]

According to the above construction, when assembling, the connecting members, both ends of which are connected to the inner surface peripheral portions of the upper and lower mirror portions, are contracted by heating, so that the upper and lower mirror portions are pulled in a direction approaching each other. The padding and the outer package can be fixed to the spring unit via the mirror portion. At the time of disassembly, the outer package and the padding can be separated from the spring unit only by cutting and removing the connecting member.

[0013]

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

FIGS. 1 to 5 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 provided on the upper and lower edges of the spring unit 1.
Are connected by a clip (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. To form a laminate 7. As the filling 6, for example, a synthetic fiber, urethane foam or the like formed to a predetermined thickness is used.

The laminate 7 of the spring unit 1 and the padding 6 is covered with an exterior body 8. The exterior body 8 includes an upper mirror portion 9 and a lower mirror portion 10 which are respectively laminated on the upper and lower surfaces of the spring unit 1, and a gusset portion 11 covering the outer peripheral surface. These mirror portions 9, 10 and the town portion 11 are respectively composed of a surface material 9a, 10a, 11a and a lining 9
b, 10b, 11b, and sheet-like urethane foam
And 9c, 10c, and 11c , and the three are integrally quilted. The upper and lower ends of the gusset 11 are integrally sewn to the periphery of the upper mirror 9 and the lower mirror 10 by a tape 12.

As shown in FIG. 3, the linings 9b and 10b of the upper and lower mirror portions 9 and 10 are arranged at predetermined intervals in the circumferential direction. On both sides, three end portions of the sheet-like first connecting member 13 are connected by sewing or bonding. The height of the first connecting member 13 is set larger than the height of the laminate 7. As shown in FIG. 3 and FIG. 4, the linings 9b, 1
Ob is connected to one end of a sheet-like second connecting member 14, respectively, and the other end of the second connecting member 14 connected to the upper mirror 9 is a lower peripheral edge of the upper side of the spring unit 1. And is temporarily fixed to the spring unit 1 by bonding or the like. Similarly, the other end of the second connecting member 14 connected to the lower mirror section 10 is provided to bend at the lower peripheral edge of the lower side of the spring unit 1.

The first and second connecting members 13 and 14 are
A relatively soft heat-shrinkable synthetic resin is formed in a sheet shape. Such resins include vinyl chloride resin, E
PT, cross-linked polyethylene resin, silicone rubber, and the like are used, and a phenomenon in which these resins are heated and then re-heated to return to the original shape is used.

Therefore, when the first connecting member 13 is heated, the sheet-like shape of the first connecting member 13 largely contracts in the vertical direction of the spring unit 1. 10 is pulled in the vertical direction of the spring unit 1, that is, in the direction approaching each other. As a result, the periphery of the filling 6 is wrapped by the first connecting member 13, and the upper and lower surfaces are pressed onto the spring unit 1 by the mirror parts 9 and 10.
To be held and fixed to the spring unit 1. At the same time, the upper and lower mirror parts 9 and 10 are also fixed to the spring unit 1 by being pulled in a direction approaching each other. When the second connecting member 14 is heated at the same time, the second connecting member 14 also thermally contracts, and the other end side engages with the upper and lower peripheral edges of the spring unit 1. The second connecting member 14 is connected to the upper and lower mirror parts 9,
Although 10 serves as a detent on the spring unit 1, the second connecting member 14 is not always required.

The gusset 11 of the exterior body 8 is formed by thermally shrinking the first and second connecting members 13 and 14.
The upper and lower ends are sewn to the periphery of the upper and lower mirror parts 9 and 10 by the tape 12 as described above.

FIGS. 5A to 5D show the steps of manufacturing the mattress device having the above-mentioned structure. FIG. 5A 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 to form a laminate 7. In the second step shown in FIG.
At predetermined intervals around the four inner surfaces of the upper and lower mirror portions 9 and 10
Is provided by connecting both ends thereof by sewing or bonding. At this time, the upper and lower mirror parts 9, 10
The lower end of the first connecting member 13 connected to one side in the longitudinal direction is not connected to the lower mirror 10 and is a free end. This is because the laminated body 7 is inserted and placed between the inner surfaces of the upper and lower mirror parts 9 and 10. Further, the first connecting member 1
3 is connected to the upper and lower mirror parts 9 and 10, and at the same time, one end of the second connecting member 14 is connected to the peripheral parts on the inner surfaces of the four corners of the upper and lower mirror parts 9.

In a third step shown in FIG. 5C, the laminate 7 is inserted and placed between the inner surfaces of the upper and lower mirror parts 9, 10 connected by the first connecting member 13. That is, the free end side of the first connecting member 13 which is not connected to the lower mirror portion 10 on one side in the longitudinal direction is lifted, and the stacked body 7 including the spring unit 1, the protective material 5 and the padding 6 is taken from that direction. Is inserted and placed between the inner surfaces of the upper and lower mirror portions 9 and 10. Thereafter, the free end of the first connecting member 13 on one side, which is not connected to the lower mirror section 10, is connected to the lining 10b of the lower mirror section 10 by bonding or the like. Since the height of the first connecting member 13 is larger than the height of the laminate 7, the laminate 7 can be easily inserted. Further, the other end of the second connecting member 14 whose one end is connected to the four corners of the upper mirror portion 9 is bent to the upper lower peripheral edge of the spring unit 1 and is temporarily fixed to the spring unit 1 by bonding or the like. Then, the other end of the second connecting member 14, one end of which is connected to the four corners of the lower mirror 10, is bent to the lower peripheral edge of the lower side of the spring unit 1.

As described above, if the laminate 7 in which the padding 6 is laminated on the upper and lower surfaces of the spring unit 1 is inserted and placed between the inner surfaces of the upper and lower mirror parts 9, 10, a fourth step shown in FIG.
As shown in (d), the laminate 7 and the upper and lower mirror parts 9, 10
Is transported into the hot air heating furnace 22 by the conveyor 21.

The temperature in the heating furnace 22 is 50 to 100 ° C., which is a temperature at which the first and second connecting members 13 and 14 can be heated and shrunk. When the first connecting member 13 is heated and contracts in the height direction of the spring unit 1, the upper and lower mirror portions 9,
10 are pulled toward each other. The padding 6 is placed on the spring unit 1 by the upper and lower mirror parts 9 and 10.
While being pressed down, a part of the peripheral portion is wrapped by the first connecting member 13 and held and fixed to the spring unit 1. At the same time, the upper and lower mirror parts 9 and 10 are also fixed to the spring unit 1. Further, the first connection member 13 is heated, and at the same time, the second connection member 14 is also heated. When the second connecting member 14 is heated, it contracts and engages with the lower peripheral edge of the spring unit 1. Thus, the upper and lower mirror portions 9 and 10 serve as a detent on the laminate 7. However, the second connecting member 14 fixes the upper and lower mirror portions 9 and 10 to the spring unit 1 more securely, but is not always necessary.

In a fifth step, the outer peripheral surface of the spring unit 1 of the stacked body carried out of the heating furnace 22 is covered with the gusset 11, and the upper and lower ends of the gusset 11 are covered with the upper mirror 9 Then, the mattress device shown in FIG. 1 is manufactured by suturing the peripheral portion of the lower mirror portion 10 with the tape 12.

According to the mattress device manufactured as described above, the paddings 6 and the upper and lower mirror portions 9 and 10 laminated on the upper and lower surfaces of the spring unit 1 are combined with the upper and lower mirror portions 9 and
A first connecting member 13 having both ends connected to the first connecting member 13
The upper and lower mirror portions 9 and 10 are fixed in the spring unit 1 by being contracted by heat in a direction in which the upper and lower mirror portions 9 and 10 approach each other. That is, the first connecting member 13 is thermally contracted and the mirror parts 9 and 10 are pulled in a direction approaching each other, so that the padding 6 and the exterior body 8 are fixed to the spring unit 1.

Therefore, the padding 6 and the upper and lower mirror portions 9 and 10 stacked on the spring unit 1 do not need to be connected to the spring unit 1 using many clips as in the related art, and the first connecting member 13 is used. Can be connected and fixed to the spring unit 1 only by thermal contraction, so that the operation of connecting and fixing the padding 6 and the upper and lower mirror parts 9 and 10 to the spring unit 1 can be performed easily, quickly and manually. Instead , it can be automated.

On the other hand, when separating the spring unit 1 from the padding 6 and the exterior body 8 in order to dispose of the mattress device having the above structure, the tape 12 having the gusset 11 connected to the mirrors 9 and 10 should be used. After removing the gusset 11 from the outer peripheral surface of the spring unit 1 or cutting a middle part in the height direction of the gusset 11 along a circumferential direction with a cutter or the like, the outer peripheral surface of the spring unit 1 is removed. The first connecting member 13 and the second connecting member 14 in the contracted state are cut with a cutter, scissors, or the like. As a result, the upper and lower mirror portions 9 and 10 are not pulled by the first connecting member 13 in a direction approaching each other.

When the upper and lower mirror portions 9 and 10 are not pulled in the direction in which they approach each other, the holding and fixing state of the padding 6 and the upper and lower mirror portions 9 and 10 is released. The padding 6 and the upper and lower mirror parts 9 and 10 can be separated. In other words, at the time of disposal, the first connecting member 13 made of a sheet-like synthetic resin provided partially on the outer periphery of the spring unit 1 is cut off by the relatively easy operation of removing the padding 6 from the spring unit 1. And exterior body 8
Can be separated.

FIG. 6 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, that is, bonded to the extent that they can be easily separated by a hot melt 31 as an adhesive.

According to such a configuration, at the time of assembling, before the first connecting member 13 is thermally contracted,
Since the protective member 5 and the padding 6 laminated on the spring unit 1 can be prevented from shifting, the assembling accuracy can be improved.

FIG. 7 shows a third embodiment of the present invention. In this embodiment, the 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 connected to the spring unit 1 by passing the thread-like member 32 through the laminate 7 and connecting the buttons 33 to both ends of the stuffing 6 respectively.
It is intended to be fixed to.

FIG. 8 shows a fourth embodiment of the present invention. In the fourth embodiment, the upper mirror portion 9 and the gusset portion 11 of the exterior body 8 are integrally formed. In the case of manufacturing a mattress device having such a configuration, the first connecting member 13 is required. After contraction, the lower end of the gusset 11 and the periphery of the lower mirror 10 need only be sewn together with a tape 12.

It is to be noted that a third portion provided around the inner surface of the mirror portion is provided.
Although the first connecting member is partially provided along the circumferential direction,
May be provided over any of the configurations.
You may.

[0035]

As described above, according to the present invention, a connecting member made of a heat-shrinkable synthetic resin is connected to the inner peripheral portions of the upper mirror portion and the lower mirror portion constituting the exterior body, and both ends thereof are connected. Then, the upper and lower mirror portions are pulled in a direction approaching each other by heating and contracting the connecting member to fix the filling and the outer package to the spring unit.

Therefore, the padding and the outer casing are fixed to the spring unit by the contraction of the connecting member.
It is not necessary to use a large number of clips as in the related art, and the connection work can be facilitated and speeded up. 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 of the synthetic resin. In addition, it is possible to easily perform the work 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 an explanatory view showing a state in which a laminate is inserted and mounted on an exterior body before heating.

FIG. 3 is an explanatory diagram showing connection positions of first and second connection members in the mirror unit.

FIG. 4 is a cross-sectional view of a corner portion of the mattress device showing an engagement state of the second connecting member.

FIG. 5 is an explanatory view of a manufacturing process of the mattress device.

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

FIG. 7 is a cross-sectional view of a part of a mattress device according to a third embodiment of the present invention.

FIG. 8 is a cross-sectional view of a part of a mattress device according to a fourth embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Spring unit 6 Stuffing 7 Laminated body 8 Exterior body 9 Upper mirror part 10 Lower mirror part 11 Town part 13 1st connection member

Claims (2)

(57) [Claims] 1. A spring unit having an upper surface and a lower surface, a padding stacked on the upper surface and a lower surface of the spring unit, an upper and lower mirror unit and an outer peripheral surface which cover upper and lower surfaces of a stacked body of the padding and the spring unit. An outer body having a covering portion and a heat-shrinkable synthetic resin, both ends of which are connected to the inner peripheral portions of the upper and lower mirror portions, respectively, and are provided in a circumferential direction on the outer peripheral surface of the spring unit. A mating device, comprising: a connecting member that pulls the upper and lower mirror portions in a direction approaching each other by being contracted and contracted. 2. A mattress device comprising: a laminate in which a filler is laminated on upper and lower surfaces of a spring unit; and an outer body comprising a mirror portion covering the filler and a gusset covering an outer peripheral surface of the spring unit. In the method, the step of laminating the padding on the upper and lower surfaces of the spring unit, and on the inner peripheral portion on three sides except one side of the upper and lower mirror portions,
A step of connecting both ends of a connecting member made of a heat-shrinkable synthetic resin; a step of inserting and placing the laminate between inner surfaces of the upper and lower mirror sections; and a connecting member on one side of the upper and lower mirror sections. And a step of contracting the connecting member by heating the connecting member and pulling the upper and lower mirror portions in a direction approaching each other.