JP2802881B2 - 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 takes a great deal of time and labor, which may reduce the productivity. In addition, the flange cloth may be clipped to the spring unit. There is also a case where a lot of time and effort is required for the work of linking.

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 separate collection is being performed, the spring unit, which is a metal part, and the padding and the outer casing made of synthetic cotton 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 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, 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; Upper and lower-pair of flange cloths provided with one end connected to the inner peripheral portion of the
On the outer peripheral surface of the spring unit, both ends are respectively connected to the other ends of the pair of upper and lower flange cloths on the outer peripheral surface of the spring unit, and the flanges are provided in the circumferential direction, and are heated and shrunk to form the flange. A connection member for applying tension to the cloth.

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 an 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 laminating, and a step of partially connecting the other end portions of the pair of upper and lower flange cloths in the circumferential direction by a connecting member formed of a fabric made of heat-shrinkable fibers on the outer peripheral surface of the spring unit; Heating the member to shrink it to apply 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 end 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 4 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 made of, for example, synthetic cotton or urethane foam 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 are integrally quilted. The upper and lower ends of the town 10 are the upper mirror 8
The lower mirror 9 is integrally sewn to the periphery of 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
A connecting member 13 is provided at predetermined intervals in the circumferential direction at a middle portion in the height direction of the spring unit 1 on the outer periphery of the other end of the connecting bar 14.
Installed by.

The connecting member 13 is formed into a thread form by twisting heat-shrinkable synthetic resin fibers, and is formed into a woven cloth or a non-woven fabric without knitting, that is, a cloth form.

As the heat-shrinkable resin forming the connecting member 13, vinyl chloride resin, EPT, PETP, cross-linked polyethylene and the like are used. These resins are molded by heating and the molded product is reheated. Utilizes the phenomenon of trying to return to the original form.

As shown in FIG. 3, the connecting bar 14 has an intermediate side 14a formed slightly longer than the width of the connecting member 13, and L-shaped bends at both ends of the intermediate side 14a. An end side 14c having a wedge-shaped retaining portion 14b formed at the end thereof is integrally formed of a material having a certain degree of rigidity, for example, synthetic resin or metal.

At the other end of the pair of upper and lower flange cloths 12, a pair of engaging holes 12a are formed at predetermined intervals in the circumferential direction. The connecting member 13 is formed such that the middle side 14a of the pair of connecting bars 14 is inserted into the loop, and the retaining portions 14b at both ends are formed at the other ends of the pair of upper and lower flange cloths 12. By being press-fitted into the engagement hole 12 a, it is attached between the pair of upper and lower flange cloths 12 in a stretched state.

Therefore, when the connecting member 13 is heated, the loop shape of the connecting member 13 contracts in the vertical direction of the spring unit 1, so that the contraction applies tension to the other end of the flange cloth 12. You. Thereby, the peripheral portion of the padding 6 is wrapped by the flange cloth 12 and held and fixed to the spring unit 1. At the same time, the mirror portions 8 and 9 connected to one end of the flange cloth 12 are also fixed to the spring unit 1 via the flange cloth 12.

After the connecting member 13 is thermally contracted, 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 11 as described above. Sewn on.

FIGS. 4A to 4D show the steps of manufacturing the mattress device having the above-mentioned structure. FIG. 4A shows a first step. In this first step, the padding 6 is laminated on the upper and lower surfaces of the spring unit 1 via the protective material 5. FIG. 4 (b)
In the second step shown in (1), one end of the flange cloth 12 is sewn around the inner surfaces of the upper and lower mirror portions 8, 9 of the exterior body 7. The second step can be performed in parallel with the first step.

In a third step shown in FIG. 4 (c), the second step is carried out between the other ends of the flange cloth 12, one end of which is sewn around the inner surfaces of the upper and lower mirror parts 8, 9. The connecting member 13 is connected by a connecting bar 14. That is, the connecting member 13 is stretched at predetermined intervals in the circumferential direction between the other end portions of the pair of upper and lower flange cloths 12. As a result, the other end of the flange cloth 12 sewn at one end to the inner peripheral portion of each of the mirror portions 8 and 9 is
The outer periphery of the filling 6 is covered. FIG. 2 shows a state in which the connecting member 13 is attached between the ends of the pair of upper and lower flange cloths 12.

As described above, if the padding 6 and the mirror parts 8 and 9 are laminated on the upper and lower surfaces of the spring unit 1 and the pair of upper and lower flange cloths 12 are connected by the connecting member 13,
As a fourth step, as shown in FIG. 4D, 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 contracts in the height direction of the spring unit 1, the other ends of the pair of upper and lower flange cloths 12 are pulled. 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 each mirror section 8 to which one end of the flange cloth 12 is connected. , 9 are also fixed to the spring unit 1.

In the fifth step, the outer peripheral surface of the spring unit 1 of the laminate 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 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 configured as described above, 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 ends of the pair of upper and lower flange cloths 12 are pulled by the connecting member 13, and are 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 portions 8 and 9 stacked on the spring unit 1 do not have to be connected to the spring unit 1 by using a large number of 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 performed easily and quickly, and not manually but automatically. be able to.

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 structure, the tape 11 in which the gusset 10 is connected to the mirrors 8 and 9 is used. After removing the gusset 10 from the outer peripheral surface of the spring unit 1, or cutting the middle part of the gusset 10 in the height direction along a circumferential direction with a cutter or the like to divide the exterior body 7 into two parts vertically. Connecting member 13 in a contracted state on the outer peripheral surface of spring unit 1
Is cut with a cutter or the like. 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 connecting member 13 made of a fabric formed of heat-shrinkable fibers partially provided on the outer peripheral surface of the spring unit 1 is cut off from the spring unit 1 by a relatively simple operation. The padding 6 and the exterior body 7 can be separated.

FIG. 5 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 assembling until the connecting member 13 is thermally contracted. Easy to assemble,
The accuracy can be improved.

FIG. 6 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. 7 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 portion 10 ′ and the peripheral portion of the lower mirror portion 9 are manufactured. Need only be sewn on the tape 11.

FIGS. 8A and 8B show a fifth embodiment of the present invention. In this embodiment, the connecting member 1 is connected to the flange cloth 12.
In a modification of the connecting means for connecting 3 ′, this connecting means has a screw member 15. This screw member 15 has a head 1 at one end.
5a, a screw portion 15b is integrally formed at the other end. A nut 16 can be screwed into the screw portion 15b.

On the other hand, the connecting member 13 'is made of cloth of a predetermined size, and a pair of first engaging holes 13a are formed at both ends thereof. At the other end of the pair of flange cloths 12, second engagement holes 12b are formed at intervals corresponding to the first engagement holes 13a.

A first engagement hole 13a formed in the connection member 13 'and a second engagement hole 13a formed in the flange cloth 12 are formed.
The coupling member 13 ′ is overlapped with the flange cloth 12 so that the engagement hole 12 b of the screw member 15 is aligned with the engagement hole 12 b of the screw member 15.
Is inserted into the first and second engagement holes 13a and 12b, and a nut 16 is screwed into a screw portion 15b protruding from the flange cloth 12, thereby connecting the connection member 13 'to the flange cloth 12. ing.

According to such a configuration, the connecting member 13 '
However, it is possible to easily and quickly connect to the flange cloth 12 even if it is not a loop shape as in the first embodiment.

Although the connecting member is provided partially in the circumferential direction of the spring unit in the above embodiment, it may be provided over the entire circumference. In addition, 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 only on the portion where the connecting member is provided. It does not matter. Further, as the connecting means, in addition to the means described in the above embodiment, a clip or a suture may be used.

[0042]

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 formed of a fabric made of heat-shrinkable fibers is partially connected in the circumferential direction of the spring unit, and tension is applied to the flange cloth by heating and shrinking the connecting member. The padding and the exterior body were fixed.

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 a large number of clips as in the related art are not required, 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 connecting member formed of the fabric made of the heat-shrinkable fiber is cut to remove the padding and the outer package. Since the mattress device can be separated from the spring unit, 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 a side view of a state before a town portion of the exterior body is attached.

FIG. 3 is a perspective view of a connecting member and a connecting bar.

FIG. 4 is an explanatory view of a manufacturing process of the mattress device.

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

FIG. 6 is a cross-sectional view of a part of a mattress device showing a third embodiment of the present invention.

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

8A is a perspective view of a connecting member and a connecting bar according to a fifth embodiment of the present invention, and FIG. 8B is a sectional view of the same inexpensive state.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Spring unit 6 Stuffing 7 Exterior body 8, 9 Mirror part 10 Town part 12 Flange cloth 13 Connection member 14 Connection bar.

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 outer body having a covering town part, a pair of upper and lower flange cloths provided with one end connected to the inner peripheral part of each of the mirror parts, and a spring cloth formed of heat-shrinkable fabric; A connecting member is provided on the outer peripheral surface, the both ends of which are connected to the other ends of the pair of upper and lower flange cloths, respectively, and is provided in the circumferential direction, and is heated and contracted to apply tension to the flange cloths. And mattress equipment. 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 ends of the pair of upper and lower flange cloths in the circumferential direction by a connecting member formed of a fabric made of heat-shrinkable fibers on the outer peripheral surface of the unit, and shrinking the heating by heating the connecting member. Applying a tension to the flange cloth.