JP3025856B2 - 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 apparatus 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. You. 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 outer body from moving relative to the spring unit, one end is connected and fixed to the inner peripheral portion of the mirror portion to provide a flange cloth, and the other end of the flange cloth is connected to the peripheral portion of the spring unit. In the same way as the filling, the clip is connected and fixed.

According to such a configuration, the padding is prevented from being displaced by the clip, and the exterior body is prevented from being displaced by the flange cloth. 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 lead to a reduction in productivity. The work can be a lot of work.

[0005] On the other hand, when the mattress device is damaged due to long-term use and must be discarded, recently, the 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. In that case, if the padding is connected to the spring unit by a large number of clips, it may not be easy to remove the padding from the spring unit, and similarly it may not be easy to remove the exterior body from the spring unit. Therefore, the disassembly work at the time of disposal may take a lot of trouble.

[0006]

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 the materials must be disassembled at the time of disposal, the disassembling operation is troublesome. The present invention has been made based on the above circumstances, and an object of the present invention is to enable the padding and the outer package to be connected to the spring unit without using a large number of clips, and to be easily disassembled. And a method of manufacturing the same.

[0007]

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 comprising a padding of a predetermined thickness laminated on at least the upper surface of the spring unit, a mirror portion covering at least the upper surface of the laminate of the padding and the spring unit, and a gusset covering the outer peripheral surface; One end is connected to the periphery of the inner surface of the mirror portion and provided along the outer periphery of the padding. The other end is formed of a heat-shrinkable synthetic resin, and is heated and contracted to engage the spring unit. And a flange portion provided with a connecting member to be combined.

[0008] A method of manufacturing a mattress device according to the present invention is a method of manufacturing a mattress device in which a laminated body in which at least upper surfaces of upper and lower surfaces of a spring unit are stuffed is covered with an exterior body comprising a mirror portion and a gusset portion. A step of laminating the padding on at least the upper surface of the spring unit, and a width direction end of a flange portion provided with a connecting member made of a heat-shrinkable synthetic resin at the other end portion around an inner surface of the mirror portion. Connecting the mirror portion to the padding so that the flange portion covers the outer periphery of the padding, and heating the laminate comprising the mirror portion, the padding, and the spring unit to connect the mirror portion to the padding. Contracting the member to engage the spring unit.

[0009]

According to the above construction, the connecting member provided at the other end of the flange portion is heated to contract the connecting member, so that the connecting member can be engaged with the spring unit. Can be easily and quickly performed, and the padding and the exterior body connected by the connecting member can be easily separated from the spring unit only by cutting and removing the connecting member made of synthetic resin.

[0010]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 3 show a first embodiment of the present invention. The mattress device shown in FIG.
Having. 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 laminated via sheet-like protective members 5 such as felt. ing. The stuffing 6 is formed of, for example, cotton, synthetic cotton, urethane foam or the like to a predetermined thickness.

A 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 town section 11 which covers the outer peripheral surface. These mirror parts 8 and 9 and the town part 11 are composed of outer materials 8a, 9a and 11a and linings 8b, 9b and 11b.
Between woven cotton and urethane foam 8c, 9c, 11c
And quilting these three together. The upper and lower ends of the gusset 11 are integrally sewn to the periphery of the upper mirror 8 and the lower mirror 9 by a tape 12.

The linings 8b and 9b of the mirrors 8 and 9 have
A main body 13a formed of a tape-shaped cloth bent in an L-shaped cross section and constituting the flange portion 13 over the entire periphery of the peripheral portion.
Are connected by means such as adhesion or sewing. The other end of the main body 13a is made of a relatively soft heat-shrinkable synthetic resin and has a tape-shaped connecting member 13b.
Are connected by means such as adhesion or sewing. As the heat-shrinkable resin forming the connecting member 13b, vinyl chloride resin, EPT, PETP, cross-linked polyethylene, silicon rubber, and the like are used. These resins are formed by heating and the molded product is reheated. Utilizes the phenomenon of trying to return to the original form. In a state where the mirror portions 8 and 9 are placed on the filling 6, one end in the width direction of the flange portion 13 is an upper surface of a peripheral portion of the filling 6 (surface opposite to the spring unit 1) as shown in FIG. 2. The middle part covers the outer peripheral surface of the padding 6, and the flange connected to the upper mirror part 8
The connecting member 13b connected to the other end of the portion 13 is a spring.
In this state, the outer peripheral surface of the locking unit 1 is covered. Lower
Connected to the other end of the flange portion 13 connected to the mirror portion 9
The connecting member 13b is a peripheral portion of the inner surface of the spring unit 1.
It is in a state of being bent. In this state,
When the binding member 13b is heated and contracted by heat, the spring
The connecting member 13b covering the outer peripheral surface of the knit 1 is bent inward.
The spring unit 1 as shown in FIG.
It will engage with the inner periphery. In addition, it is connected to the upper mirror section 8.
Connect the connecting member 13b of the connected flange portion 13 with a spring.
Several places in the circumferential direction of the unit 1
Spring unit 1 by bending to inner peripheral edge and bonding etc.
The connecting member 13b was shrunk by heating.
Sometimes, the connecting member 13b is more securely connected to the spring unit.
1 can be engaged. And the town of the exterior body 7
The part 11 heat shrinks the connecting member 13b,
The upper and lower ends are taped around the mirrors 8 and 9.
Is sutured as described above.

FIGS. 3A to 3D show the steps of manufacturing the mattress device having the above-described structure. FIG. 3 (a) shows the first
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. 3B shows a second step which is performed at the same time as the first step. In the second step, the linings 8b and 9b of the upper mirror part 8 and the lower mirror part 9 are formed around the inner surface. One end in the width direction of the flange portion 13 in which the connecting member 13b is connected to the other end of the main body 13a in advance by means such as bonding or sewing is fixed by bonding or sewing. In the third step shown in FIG.
Padding 6 laminated on the upper and lower surfaces of the spring unit 1
The upper mirror 8 and the lower mirror 9 to which the flange 13 provided with the connecting member 13b is fixed are stacked.

The spring unit 1 on which the mirror portions 8 and 9 are mounted in the third step is carried into the hot air heating furnace 22 by the conveyor 21 in the fourth step shown in FIG. In the hot air heating furnace 22, the air is heated to 50 to 130 ° C. by the hot air. It was but connexion, coupling member 13b is thermally contracted in the flange portion 13 provided on the inner surface of the mirror 8 and 9, while bending the body 13a to the spring unit 1 side, the upper
The inner surface of the spring unit 1 is engaged with the peripheral portion. As a result, each of the mirror portions 8 and 9 to which one end of the flange portion 13 is connected and fixed is connected to the spring unit 1 and provided between each of the mirror portions 8 and 9 and the upper and lower surfaces of the spring unit 1. Each filling 6 is also the above spring unit 1
Will be fixed to. That is, the stacked body of the spring unit 1, the padding 6, and the mirror parts 8, 9 is integrally connected. 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 11, and the upper and lower ends of the gusset 11 are covered with the upper mirror 8 and the lower mirror. Tape 12 around part 9
As a result, the mattress device shown in FIG. 1 is manufactured.

According to the mattress device manufactured 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 combined with the flange portions 13 provided on the mirror portions 8 and 9. The connection member 13 b is thermally contracted and engaged with the spring unit 1, thereby being connected to the spring unit 1. In other words, the padding 6 and the mirror parts 8 and 9 stacked on the spring unit 1 are not connected to the spring unit 1 by using many clips as in the prior art, and the spring unit is simply contracted by thermal contraction of the connection member 13b. 1 can be connected and fixed. Therefore, 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 promptly and automatically without manual operation.

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 12 having the gusset 11 connected to the mirrors 8 and 9 is used. Remove and remove the gusset 11 or leave the gusset 11 connected to the mirrors 8 and 9
After cutting the periphery of the center portion with a cutter or the like, a notch is cut into the connecting member 13b engaged with the spring unit 1 with a cutter or the like, and the connecting member 13b is torn in the circumferential direction of the spring unit 1 from the cut portion. The engagement between the flange 13 and the spring unit 1 can be released. Thereby, the padding 6 and the mirror parts 8 and 9 can be separated from the spring unit 1.
That is, at the time of disposal, the padding 6 and the outer package 7 can be separated from the spring unit 1 by an easy operation of tearing the connecting member 13 formed of a tape-shaped relatively soft synthetic resin.

FIG. 4 shows a second embodiment of the present invention. In this embodiment, the outer body 7 in which the gusset 11 covering the outer peripheral surface of the spring unit 1 is formed continuously and
Is a mattress device using the same. That is, the upper mirror portion 8 covers the stuffing 6 and further descends from the outer peripheral surface of the stuffing 6 to cover the outer peripheral surface of the spring unit 1, and its peripheral edge is sewn to the peripheral edge of the lower mirror portion 9 by the tape 12. ing.

FIG. 5 shows a third embodiment of the present invention. This embodiment is a mattress device using a connecting member 13b connected to the other end of the flange portion 13, the tip of which is formed in a pipe shape.

FIG. 6 shows a fourth embodiment of the present invention. In this embodiment, a protective material 5 is provided on the upper and lower surfaces of the spring unit 1.
The padding 6 laminated via the above is partially adhered together with the protective material 5 by the hot melt 31. The hot melt 31 connecting member 13b is at a temperature lower than the temperature at which shrinkage, for example those which cure at about 50 ° C. Temperature is used. As described above, if the fillings 6 are laminated by the hot melt 31, the hot melt 31 is hardened and the fillings 6 are fixed to the spring unit 1 before the connecting member 13b thermally contracts. Therefore, even if the thermal contraction of the connecting member 13b does not progress uniformly in the circumferential direction, the padding 6 does not move on the spring unit 1. Moreover, since the adhesive fixation to the filling 6 by the hot melt 31 is partial, the filling 6 can be easily separated from the spring unit 1 at the time of disassembly. In this case, the filling 6 and the spring unit 1 may be partially connected in advance by the hot melt 31 before the connecting member 13b is contracted by heating.

FIG. 7 shows a fifth embodiment of the present invention. In this embodiment, the thread member 32 is passed through the paddings 6 stacked on the upper and lower surfaces of the spring unit 1, and buttons 33 are attached to both ends of the threading member 32, whereby the padding 6 is fixed to the spring unit 1. . According to such a configuration, the padding 6 can be fixed to the spring unit 1 in advance, so that the stacked body of the spring unit 1, the padding 6, and the mirror parts 8, 9 can be handled before the connecting member 13b is contracted. It will be easier.

In the above embodiment, the so-called double-sided mattress device in which the padding 6 and the mirror of the exterior body are provided on the upper and lower surfaces of the spring unit, respectively, has been described. The present invention can also be applied to a so-called bottom mattress in which only a padding is provided and the upper surface and the outer peripheral surface are covered with an exterior body.

[0023]

As described above, the present invention is directed to a flange portion in which a connecting member formed of a heat-shrinkable synthetic resin is provided at the other end portion around the inner surface of a mirror portion constituting an exterior body. One end is connected, and the connecting member is thermally contracted and engaged with the spring unit, so that the padding laminated on the spring unit and the exterior body of which the mirror part forms a part are fixed to the spring unit. I did it. Therefore, the padding and the outer package can be connected and fixed to the spring unit without using a large number of clips as in the related art, so that the connecting operation can be performed easily and quickly. In addition, since the operation of thermally shrinking the connecting member can be easily automated, the productivity can be improved thereby. Further, when the mattress device having the above configuration is discarded in an area where the sorting and collection is performed, by tearing the synthetic resin connecting member, the exterior body and the padding can be easily separated from the spring unit. The operation of dividing the components constituting the mattress device for each material can be easily performed.

[Brief description of the drawings]

FIG. 1 is a cross-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 gusset 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 sectional view of a part of a mattress device showing 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.

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

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Spring unit, 6 ... Stuffing, 7 ... Outer body, 8, 9 ... Mirror part 11 ... Town part, 13 ... Flange part, 13b ... Connection member.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) A47C 27/045-27/05 A47C 31/02

Claims (2)

(57) [Claims] 1. A spring unit having an upper surface and a lower surface, a padding laminated on at least an upper surface of the splicing unit, and a mirror part and an outer peripheral surface covering at least an upper surface of a laminated body of the padding and the spring unit. An exterior body having a gusset, and one end in the width direction connected to the inner peripheral portion of the mirror portion and provided along the outer peripheral portion of the padding, and the other end portion formed of a heat-shrinkable synthetic resin and heated. And a flange provided with a connecting member engaged with the spring unit by being thermally contracted. 2. A method of manufacturing a mattress device comprising a laminate in which a padding is laminated on at least the upper and lower surfaces of an upper and lower surfaces of a spring unit with an exterior body having a mirror portion and a gusset portion. A step of laminating the padding on the upper surface, and a step of connecting one end in the width direction of the flange portion provided with a connecting member made of a heat-shrinkable synthetic resin at the other end portion on the inner peripheral portion of the mirror portion, A step of laminating the mirror portion to the padding so that the flange portion covers the outer periphery of the padding, and heat-shrinking the connecting member by heating a laminate comprising the mirror portion, the padding and a spring unit; And a step of engaging with a spring unit.