JP3129797B2 - Futon manufacturing method and manufacturing apparatus - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a futon in which a futon fabric is sewn into a plurality of blocks to form a floating pattern such as a lattice while filling a filling such as feathers into a bag-like futon fabric. The present invention relates to a manufacturing method and a manufacturing apparatus.

[0002]

2. Description of the Related Art In recent years, duvets have been widely used as bedding for bedclothes. In this duvet, a predetermined amount of feathers are filled in the futon fabric, and the front and back of the futon fabric are sewn into a plurality of blocks, thereby preventing deviation of the down and forming a floating pattern such as a lattice. Is common.

[0003] As a method of manufacturing such a duvet, a predetermined amount of feathers are filled in a sewn futon fabric, and then the front and back sides of the futon fabric are sewn in a block shape, and then the opening is opened. The edges are stitched together.

[0004]

As described above, in the method of sewing the blocks after filling the interior of the futon cloth with the feathers, even if the sewing is performed by a machine such as a sewing machine, the blocks are hindered by the feathers and the smoothness is obtained. In addition, if the sewing machine becomes difficult to operate, or if there is a bias when the down is filled in the futon fabric, the futon is completed as it is.

The present invention has been made in view of the above circumstances, and provides a method of manufacturing a futon that can smoothly sew a block without being affected by feathers and does not cause unevenness of feathers. It is an object.

[0006]

Means for Solving the Problems The present invention has been made to achieve the above-mentioned object. According to a first aspect of the present invention, a plurality of futon doughs are filled in a bag-like futon dough while filling with batting or other batting. A method of manufacturing a futon, wherein sewing is performed on a block to form a floating pattern such as a lattice, and the plurality of blocks are sewn while leaving a batting filling port, and then a predetermined amount is inserted into each block from the batting filling port. After filling the batting, the step of closing and forming each block by sewing the batting filling port is sequentially repeated from the bottom opposite to the opening end of the futon fabric toward the opening end. Features.

According to a second aspect of the present invention, the futon fabric is sewn into a plurality of blocks to form a floating pattern such as a lattice while filling the inside of the bag-like futon fabric with batting or the like.
A futon manufacturing apparatus, wherein a trolley on which the futon fabric is placed flat and a futon fabric are inserted from the open end of the futon fabric into the interior of the futon fabric, and the batting is filled in the block. A plurality of batting filling pipes extending in the longitudinal direction of the futon fabric over the bottom opposite to the open end, and a sewing machine mechanism arranged above the bogie and sewing the block is provided, and the bogie and the batting filling pipe are provided. And the carriage and the sewing machine mechanism are provided so as to be relatively movable along the longitudinal direction of the futon fabric, and to be relatively movable along the longitudinal direction of the futon fabric.

[0008]

[Function] After the block is sewn on the futon fabric, the batting is filled in the block, so that the sewing by the sewing machine mechanism is not affected by the batting, so that the sewing machine mechanism operates smoothly and the sewing time is increased. Since the block is shortened and the predetermined amount of batting is filled in the block, the batting is not biased and a good quality futon can be obtained.

[0009]

An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 schematically shows a futon manufacturing apparatus 1 according to the present invention and a feather supply facility 2 for supplying feathers to the futon manufacturing apparatus 1.

First, the feather supply facility 2 will be described. The feather supply facility 2 includes two feather tanks 3 and 4 for storing a large amount of feathers, and four feather filling machines 5, 6, 7 and 8. When,
The feathers in the feather tanks 3, 4 are filled with the respective feather filling machines 5, 6,
Supply pipes 9 and 10 for supplying the supply pipes 7 and 8 to the supply pipes;

Different feathers such as down and feather are stored in the two feather tanks 3 and 4, for example. These feathers are supplied from the supply pipes 9 and 10 to the respective feather filling machines 5, 6 and 7 and 8 are sent. These feather filling machines 5, 6, 7, 8 mix the two types of feathers sent from the feather tanks 3, 4 at an arbitrary ratio, and distribute the feathers from the distribution pipes 11a, 11b, 11c, 11d connected to the respective feathers. , And is sent to the futon manufacturing apparatus 1.

The futon fabricating apparatus 1 is inserted into the futon fabric H from the open end of the trolley 12 on which the rectangular futon fabric H previously sewn in a bag shape is placed flat, and from the opening end of the futon fabric H. It is provided with four feather filling tubes 13a, 13b, 13c, 13d for filling feathers into the futon fabric H, and a sewing machine mechanism 14 arranged above the carriage 12 for sewing the futon fabric H.

The trolley 12 has a rectangular work board 16 having a size large enough to place one futon fabric H on a frame 15, and the frame 15 is placed on a base 17. The work board 16 is installed so as to move horizontally along the length direction of the work board 16 (in the direction of arrow Q in FIG. 1, hereinafter, this direction will be referred to as the front-rear direction, and the direction perpendicular thereto will be referred to as the lateral direction). The base 17 has a length of about 2
A main table 17a having a double length and extending toward the feather supply facility 2 and closer to the feather supply facility;
In addition, the sub-table 17b is connected thereto, and the carriage 12 moves between both ends thereof. The carriage 12 is moved by the action of a ball screw 18 attached to the base 17.

The feather filling tubes 13a to 13d are connected to the distribution pipes 11a to 11d, respectively, and are arranged on the main table 17a of the base 17 at equal intervals in parallel and along the front-back direction. It extends horizontally. These feather filling tubes 13a to 13d are arranged at a height slightly higher than the work board 16, and their ends facing the sub-table 17b are cut so as to open upward. .

The sewing machine mechanism 14 is provided at an end of the main table 17a of the base 17 on the side of the sub-table 17b, and is fixed between both ends in the horizontal direction of the sub-table 17b. And a beam portion 1 of the frame 18
8b, there are provided a plurality of sewing heads 19 attached to the surface on the side of the sub-table 17b, and a sewing machine bed 20 arranged below the sewing head 19 across both legs 18a.

The sewing machine head 19 is used to sew the futon cloth H on the sewing machine bed 20 by a sewing needle (not shown) extending downward. In this case, five sewing heads 19a to 19e are provided. Each slide plate 22 is attached to a slide plate 22 via an elevating mechanism 21. The slide plate 22 slides on the beam portion 18b along a length direction (lateral direction) of the beam portion 18b via a guide rail 23. Mounted as possible. That is, the sewing head 19 is provided so as to be slidable in the lateral direction with respect to the beam portion 18b and to be able to move up and down by the elevating mechanism 21.

The truck 12 and each of the feather filling tubes 13a to 13a.
13d is the futon fabric H placed on the work board 16
Is relatively movable along the longitudinal direction of the
The sewing machine mechanism 2 and the sewing machine mechanism 14 are provided so as to be relatively movable along the longitudinal direction of the futon fabric H.

Next, the operation of the futon manufacturing apparatus 1 and the feather supply equipment 2 will be described.
4.

First, each sewing head 1 of the sewing machine mechanism 14
9a to 19e are raised to be in a standby state. Then, the futon fabric H sewn in a bag shape in advance is placed on the work board 16 of the cart 12 with the open end in the direction of the feather supply equipment 2 (hereinafter, this direction will be described as backward and the opposite direction will be described as forward). Then, the carriage 12 is retracted, whereby the feather filling tubes 13a to 13d are inserted into the futon fabric H, and the carriage 12 is positioned on the main table 17a. The bottom end of the futon fabric H opposite to the open end is disposed on the sewing machine bed 20.

Then, as shown in FIG. 2, the second to fifth sewing heads 19b to 19e are lowered, and the four sewing heads 19b to 19e perform the horizontal sewing shown in (1). As shown in 2), the first sewing machine head 19a is lowered, and the first to fifth sewing machine heads 19a to 19a.
The vertical sewing shown in (3) is performed by 19e. Next, (4)
After raising the first sewing head 19a as shown in FIG.
As in (5), horizontal sewing is performed for about half the length in the case of (1). As described above, the square block 26 in which the feather filling port 25 is formed between the sewing operations (3) and (5) is sewn in four horizontal directions. In the case of horizontal sewing, the sewing head is moved in the horizontal direction, and the vertical sewing is performed by moving the carriage 12.

As shown in (6), the carriage 12 is retracted to an appropriate length, and the distal ends of the feather filling tubes 13a to 13d are inserted from the feather filling ports 25 into the respective blocks 26. (7)
As described above, each block 26 is filled with a predetermined amount of feather through the distribution pipes 11a to 11d and the feather filling pipes 13a to 13d by the feather filling machines 5 to 8.

The trolley 12 is advanced to pull out the feather filling tubes 13a to 13d from the inside of each block 26, and the horizontal sewing portion of the above (5) is placed on the sewing machine bed 20, and the feather filling ports 25 are set to ( As shown in 9), it is sewn sideways and closed.

Next, as shown in FIG.
The sewing machine heads 19b to 19e of the first to fifth
After the sewing machine heads 19a to 19e are idle-fed as shown in (11) and lowered as shown in (12), the operation after (3) is repeated.

As described above, each of the sewing machine heads 19a-1
9e, horizontal sewing and vertical sewing are performed to sew the block 26 with the feather filling port 25 left.
The feather filling tubes 13a to 13d are inserted therein to fill the feathers, and then the feather filling tubes 13a to 13d are extracted, and the feather filling port 25 is sewn and closed. From the bottom opposite to the opening end. Then, when the horizontal sewing of the portion close to the opening end is completed, and the opening end is further sewn and closed, a duvet having a lattice-like floating pattern of a large number of square blocks 26 is completed. FIG. 3 is a flowchart of the above operation.

As described above, according to the method of manufacturing a duvet by the futon manufacturing apparatus 1 of the present embodiment, first, the block 26 is sewn on the futon fabric H, and then the block 2 is sewn.
Since the feathers are filled in the sewing machine 6, the sewing by the sewing machine mechanism 14 is not affected by the feathers. Therefore, the sewing machine mechanism 14 operates smoothly and the sewing time is shortened.

Since each block 26 is filled with a predetermined amount of feathers, the feathers are not biased, and a good quality duvet can be obtained.

[0027]

As described above, according to the futon manufacturing method of the present invention, after the block is sewn on the futon fabric, the batting is filled in the block. The sewing machine mechanism operates smoothly and the sewing time is shortened, and the block is filled with a predetermined amount of batting. Obtainable. Further, according to the futon manufacturing apparatus of the present invention, the above method can be easily and accurately performed.

[Brief description of the drawings]

FIG. 1 is an overall perspective view of a futon manufacturing apparatus and a feather supply facility according to one embodiment.

FIG. 2 is a perspective view for explaining a sewing operation on a futon cloth.

FIG. 3 is a flowchart of the operation.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Futon manufacturing apparatus 12 Dolly 13a, 13b, 13c, 13d Feather filling tube 14 Sewing machine mechanism 25 Feather filling port 26 Block H Futon fabric

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) D05B 11/00 D05B 25/00

Claims (2)

(57) [Claims] 1. A method of manufacturing a futon, wherein the futon fabric is sewn into a plurality of blocks to form a lattice-like floating pattern while filling the inside of the bag-like futon fabric with batting or the like. Sewing the plurality of blocks while leaving the batting filling port, and then filling a predetermined amount of the batting into each block from the batting filling port, and then closing the batting filling port to form each block. The method of manufacturing a futon characterized in that the step of performing is sequentially repeated from the bottom opposite to the open end of the futon fabric toward the open end. 2. An apparatus for manufacturing a futon, wherein the futon fabric is sewn into a plurality of blocks to form a lattice-like floating pattern while filling the inside of the bag-like futon fabric with batting or the like. A trolley on which the futon fabric is laid flat; and a bottom portion opposite to the open end from the open end for being inserted into the futon fabric from the open end of the futon fabric and filling the batting in the block. A plurality of batting filling tubes extending in the longitudinal direction of the futon fabric, and a sewing machine mechanism arranged above the bogie to sew the block. The bogie and the batting filling tube are arranged in the longitudinal direction of the futon fabric. A futon manufacturing apparatus, wherein the trolley and the sewing machine mechanism are relatively movable along a vertical direction of the futon fabric.