JP6446319B2 - Continuous pocket coil spring array, continuous pocket coil spring array manufacturing method, and continuous pocket coil spring array manufacturing apparatus - Google Patents

Description

  The present invention relates to a continuous pocket coil spring array used in furniture such as chairs and sofas and bedding such as a bed mattress, a manufacturing method thereof, and a manufacturing apparatus thereof.

  Regarding such a continuous pocket coil spring array and a manufacturing apparatus (manufacturing method) thereof, a technique disclosed in the following Patent Document 1 is known. The apparatus disclosed in this document includes a cassette for guiding the pocket material in order to form a cylinder of the pocket material (strip-shaped sheet material). This cassette includes a first element and a second element, and is configured such that a pocket material is folded from both sides in the width direction and shaped into a rectangular cylinder, and a coil spring is accommodated in the cylindrical space (summary). And claim 1). In order to heat seal the pocket material in order to enclose the coil spring, a heat sealing device for sealing the pocket material along the width direction on the downstream side of the cartridge, and for sealing the pocket material along the longitudinal direction A heat seal device is provided (see FIG. 3 of Patent Document 1).

Special table 2014-529553 gazette

  However, the continuous pocket coil spring array manufactured by the manufacturing apparatus has the following problems. At the position where the end portion of the first element and the end portion of the second element face each other, the end portion of the pocket material is bent vertically, and the vertically bent end portions face each other and are sealed by a heat sealing device. I have to.

  Therefore, in the center portion in the width direction of the manufactured continuous pocket coil spring row, the sealed portion protrudes by the amount bent vertically. The presence of such protruding portions may cause unpleasant irregularities when forming a sofa or mattress.

  This invention is made | formed in view of the said situation, and is providing the continuous pocket coil spring row | line | column and its manufacturing apparatus in which the unnecessary protrusion part is not formed in the external shape.

In order to solve the above problems, the continuous pocket coil spring array according to the present invention is:
A continuous pocket coil spring row formed in a row by storing one coil spring in one bag of a continuous cylindrical bag formed in a pocket shape by a belt-like sheet material having air permeability,
The continuous cylindrical bag has a structure in which a coil spring is accommodated in a space formed by folding the belt-shaped sheet material from both sides in the width direction, and along the width direction at a predetermined pitch along the longitudinal direction of the belt-shaped sheet material. And is formed by welding the longitudinal ends of the belt-like sheet material folded,
The longitudinal ends overlap each other in a vertical plane with a first longitudinal end folded from one side in the width direction and a second longitudinal end folded from the other side in the width direction. And the welding position is located at the center in the width direction.

  The operation and effect of the continuous pocket coil spring array having such a configuration is as follows. First, the continuous cylindrical bag has a structure in which a coil spring is accommodated in a space formed by folding a belt-like sheet material from both sides in the width direction. It welds along a width direction with a predetermined pitch along the longitudinal direction of a strip-shaped sheet material. A space in which the coil spring is accommodated is partitioned by this welding. In addition, when welding the longitudinal ends of the belt-shaped sheet material, the first longitudinal ends folded from one side in the width direction and the second longitudinal ends folded from the other side in the width direction Are welded in a state where they are overlapped in a vertical plane. It is possible to prevent unnecessary protruding portions from being formed on the outer shape by overlapping in a plane.

In order to solve the above problems, a method for manufacturing a continuous pocket coil spring array according to the present invention is as follows.
A method for producing a continuous pocket coil spring array in which one coil spring is housed in one bag of a continuous cylindrical bag formed into a pocket shape by a belt-like sheet material having air permeability,
Folding the strip-shaped sheet material from both sides in the width direction to form a space for accommodating a coil spring; sequentially housing the coil spring in the space; and after receiving the coil spring, A step of welding along the width direction at a predetermined pitch along, and a step of welding the longitudinal ends of the belt-shaped sheet material folded,
The longitudinal ends overlap each other in a vertical plane with a first longitudinal end folded from one side in the width direction and a second longitudinal end folded from the other side in the width direction. It is characterized by being welded in a heated state.

  The manufacturing method of the continuous pocket coil spring row | line | column by this structure forms the space in which a coil spring is accommodated by folding a strip | belt-shaped sheet | seat material from the both sides of the width direction, but the 1st longitudinal direction edge part folded from the one side of the width direction And the second longitudinal direction end members folded from the other side in the width direction are welded in a state where they are overlapped in the vertical plane. It is possible to prevent unnecessary protruding portions from being formed on the outer shape by overlapping in a plane. Note that the order of the manufacturing steps is not limited to the order described above, and can be changed as necessary.

A manufacturing apparatus for manufacturing a continuous pocket coil spring array according to the present invention is as follows.
An inner shaping part formed in a quadrilateral cross section;
A first outer shaping portion for folding the belt-like sheet material from one side in the width direction, located on the outer surface side of the inner shaping portion, forming a gap with the outer surface,
A second outer shaping part for folding the belt-like sheet material from the other side in the width direction, located on the outer surface side of the inner shaping part, forming a gap with the outer surface,
The first outer shaping portion and the second outer shaping portion have an overlapping portion having a gap at the center in the width direction,
In the overlapping portion, one of the first longitudinal end and the second longitudinal end is configured to be able to pass through a gap between the overlapping portions, and the first longitudinal end and the second longitudinal Any one of the direction end portions is configured to be able to pass under the overlapping portion.

  The operation and effect of the manufacturing apparatus having such a configuration is as follows. An inner shaping part, a first outer shaping part, and a second outer shaping part are provided for shaping the belt-like sheet material into a predetermined shape. One of the strip-shaped sheet members in the width direction passes through a gap formed between the inner shaping portion and the first outer shaping portion. Thus, the belt-like sheet material is folded from one side in the width direction. The other in the width direction of the belt-like sheet material passes through a gap formed between the inner shaping portion and the second outer shaping portion. Accordingly, the belt-like sheet material is folded from the other side in the width direction. The first outer shaping portion and the second outer shaping portion have an overlapping portion having a gap at the center in the width direction. Either the first outer shaping portion or the second outer shaping portion may be on the overlapping portion. Assume that the second outer shaping portion is on the top. In this case, the second longitudinal end portion overlaps the first longitudinal direction end portion in the vertical direction. Accordingly, it is possible to manufacture a continuous pocket coil spring array that does not form unnecessary protruding portions on the outer shape. In addition, the up-down direction which is a direction to overlap does not indicate the actual product direction but is referred to as such for convenience.

  In the present invention, a welding portion for welding the first longitudinal end and the second longitudinal end is provided on the upper side of the inner shaping portion and on the downstream side of the overlapping portion. Preferably it is.

  According to this configuration, the first longitudinal direction end portion and the second longitudinal direction end portion can be welded by the welding portion in a state where the first longitudinal direction end portion and the vertical direction overlap in a plane.

Perspective view showing appearance of continuous pocket coil spring array Sectional drawing along the longitudinal direction of the continuous pocket coil spring row | line | column of FIG. Sectional drawing along the width direction of the continuous pocket coil spring row | line | column of FIG. The perspective view which shows notionally the structure of the continuous pocket coil spring row | line | column manufacturing apparatus View A of the manufacturing apparatus shown in FIG. It is a perspective view which shows a manufacturing process notionally. It is a perspective view which shows a manufacturing process notionally. It is a perspective view which shows a manufacturing process notionally. It is a perspective view which shows a manufacturing process notionally. Sectional view showing the manufacturing process Sectional view showing the manufacturing process Sectional view showing the manufacturing process

  A preferred embodiment of a continuous pocket coil spring array and a manufacturing apparatus thereof according to the present invention will be described with reference to the drawings.

<Construction of continuous pocket coil spring array>
FIG. 1 is a perspective view showing an appearance of a manufactured continuous pocket coil spring array. FIG. 2 is a cross-sectional view taken along the longitudinal direction of the continuous pocket coil spring array of FIG. FIG. 3 is a cross-sectional view taken along the width direction of the continuous pocket coil spring array of FIG.

  The belt-like sheet material 1 is used to accommodate the coil spring in the continuous pocket coil spring array. As the belt-like sheet material 1, for example, a non-woven fabric with good air permeability is used. The type of nonwoven fabric is not limited to a specific type. As shown in FIGS. 1 and 2, a pocket-shaped cylindrical bag 10 in which one coil spring 2 is accommodated is continuously formed along the longitudinal direction. The boundary between the cylindrical bags 10 adjacent in the longitudinal direction is a welding region 11, which is welded by a heat seal device described later.

  As shown in FIG. 3, when viewed in cross section, the cylindrical bag 10 is composed of a bottom surface portion 100, a left side surface portion 101, a right side surface portion 102, a left upper surface portion 103, and a right upper surface portion 104, and the right end side of the left upper surface portion 103 is in the first longitudinal direction. The end 1a, and the left end of the right upper surface 104 is the second longitudinal end 1b. 3 is obtained by folding the flat belt-like sheet material 1 originally. The cross-sectional shape is substantially a quadrilateral. In addition, although the above-mentioned name is given for convenience, it has nothing to do with the posture when actually used. For example, in the product, the left side surface portion 101 and the right side surface portion 102 may be on the top. In addition, the coil spring 2 is accommodated in a state where it is accommodated and compressed by a predetermined amount. The quadrilateral shape is not limited to a square shape, a rectangular shape, or the like, and the aspect ratio is not limited to a specific shape or size.

  In FIG. 3, the band-shaped sheet material 1 is folded on the left side (corresponding to one side) in the width direction and is folded on the right side (corresponding to the other side) in the width direction. As shown in FIG. 3, the first longitudinal end 1a and the second longitudinal end 1b are overlapped in the vertical direction, and the overlapping portion 12 is welded. The length in the width direction of the overlapping region 12 can be set as appropriate. Since the height (planar position) of the overlapping region 12 is the same as or substantially the same as the left upper surface portion 103 and the right upper surface portion 104, it does not protrude upward.

<Continuous pocket coil spring array manufacturing device>
Next, a manufacturing apparatus for manufacturing the continuous pocket coil spring array shown in FIGS. 1 to 3 will be described with reference to FIGS. In these drawings, the belt-like sheet material is not drawn. FIG. 4 is a perspective view showing the main configuration of the apparatus. FIG. 5 is an arrow A in FIG.

  A first inner shaping plate 30 and a second inner shaping plate 31 that function as an inner shaping portion are provided. As shown in FIG. 5, the left first inner shaping plate 31 has a C-shaped cross section, and the right second inner shaping plate 31 has a reverse C-shaped cross section. These first and second inner shaping plates 30 and 31 are arranged symmetrically. The inner shaping portion may be constituted by a single plate member instead of being constituted by a plurality of members like the first and second inner shaping plates. The number of members is not limited. Moreover, you may comprise by members of shapes other than a plate.

  A first outer shaping plate 32 (corresponding to a first outer shaping portion) is arranged on the surface of the first inner shaping plate 30, and a second outer shaping plate 33 (second outer shaping plate 33) is arranged on the surface of the second inner shaping plate 31. Corresponding to the part). These first and second outer shaping plates 32 and 33 have an inverted L-shaped cross-sectional shape. In FIG. 5, the cross-sectional shape of the inner shaping portion is configured to be substantially a quadrilateral (square or rectangular). The angle of the quadrilateral is 90 degrees, but it may be rounded in an appropriate size (R shape).

  Moreover, the 1st outer shaping plate 32 and the 2nd outer shaping plate 33 have the overlap part 34 in the center part of the width direction. A side gap g1 and an upper face gap g3 are formed between the first outer shaping plate 32 and the first inner shaping plate 30. The side surface gap g1 and the upper surface gap g3 are orthogonal to each other, so that the belt-like sheet material passes between these gaps in a state where it is forcibly folded. A side gap g2 is formed between the second outer shaping plate 33 and the second inner shaping plate 31, and the belt-like sheet material 1 passes through this gap. In the overlapping portion 34, a gap g4 is formed between the first outer shaping plate 32 and the second outer shaping plate 33, and the belt-like sheet material 1 passes through the gap g4.

  A spring guide tube 40 is further provided inside the inner shaping portion. The spring guide cylinder 40 has a substantially rectangular cross-sectional shape, and the coil spring 2 is inserted from the side via the spring insertion cylinder 42. The coil spring 2 is manufactured by a spring manufacturing apparatus (not shown), and is pushed into the spring guide cylinder 40 one by one. A spring feed tube 42 is provided on the right side surface of the spring guide tube 40, and the coil springs 2 are fed one by one through the spring feed tube 42. The coil springs 2 are pushed into the spring guide tube 40 one by one in a compressed state. The coil springs 2 that have been pushed in are fed forward by the spring feed member 41 one by one.

  The first outer shaping plate 32 has an inclined end portion 32a on the side surface portion, and also has an inclined end portion 32b on the upper surface portion. Similarly, the second outer shaping plate 33 also has inclined end portions 33a and 33b. The left and right first and second inner shaping plates 30 and 31 are disposed with a gap on the upper surface side. From this gap, the upper surface of the spring guide tube 40 is exposed. The distal end on the downstream side of the spring guide tube 40 is arranged to be at the same position as the distal end on the downstream side of the inner shaping portion.

  A first pressure bonding part 50 of a first heat seal device (corresponding to welding means) is provided on the downstream side of the overlapping part 34. A first crimp receiving portion 51 is provided corresponding to the first crimp portion 50. The first crimp receiving part 51 is provided on the upper surface of the spring guide tube 40 and is welded by sandwiching and heating the belt-like sheet material 1 between the first crimping part 50 and the first crimp receiving part 51. . The first heat sealing device performs welding along the longitudinal direction in which the belt-like sheet material 1 is conveyed.

  A second pressure-bonding part 52 and a second pressure-bonding receiving part 53 constituting the second heat seal device are provided downstream of the inner shaping part and the outer shaping part. This 2nd heat seal apparatus welds the strip | belt-shaped sheet | seat material 1 along the width direction, and, thereby, the cylindrical bag in which the one coil spring 2 is accommodated is formed. The point that the belt-like sheet material 1 is sandwiched and welded between the second pressure-bonding portion 52 and the second pressure-bonding receiving portion 53 is the same as that of the first heat-sealing device. In this state, it also has a function of moving a predetermined amount downstream. Thereby, the strip | belt-shaped sheet material 1 can be intermittently conveyed with a predetermined pitch.

<Manufacturing process>
Next, a process of manufacturing the continuous pocket coil spring array shown in FIGS. 1 to 3 using the manufacturing apparatus shown in FIGS. 4 and 5 will be described. 6A to 6D are perspective views conceptually showing the manufacturing process. 7A to 7C are cross-sectional views showing the manufacturing process.

  FIG. 6A shows a process of actually pulling out the belt-like sheet material 1 from the roll 1R and accommodating the coil spring 2 therein. A state in which the belt-like sheet material 1 is passed through the gap between the inner shaping portion and the outer shaping portion is shown in the sectional view of FIG. 7A.

  7A, the belt-like sheet material 1 is folded from both sides in the width direction, but the left side surface portion 101 of the belt-like sheet material 1 is located in the left side surface gap g1, and the left top surface portion 103 is located in the top surface gap g3. Thus, the belt-shaped sheet material 1 is folded from the left side (one side) in the width direction. The right side surface portion 102 of the belt-like sheet material 1 is located in the right side surface gap g2, and the right upper surface portion 104 is located in the gap g4 in the overlapping portion 34. In this state, the first outer shaping plate 32 is located between the first longitudinal end 1a and the second longitudinal end 1b. The first and second longitudinal end portions 1a and 1b are shaped so as to overlap in the vertical direction. Thus, the belt-like sheet material 1 is folded from the right side (the other side) in the width direction.

  The coil spring 2 is accommodated in a compressed state in the spring guide tube 40. Although it is accommodated in the spring guide tube 40, it is not yet directly accommodated in the belt-like sheet material. As shown in FIG. 6A, the first pressure-bonding portion 50 moves downward at approximately the same timing as the coil spring 2 is pushed into the spring guide tube 2 to sandwich the first and second longitudinal end portions 1a and 1b. And crimp. This state is shown in FIG. 7B.

  FIG. 7B is a cross-sectional view on the downstream side of the overlapping portion 34. At this position, the first and second outer shaping plates 32 and 33, that is, the overlapping portion 34 does not exist. Therefore, the first and second longitudinal end portions 1a and 1b are crimped and melted by the first crimping portion 50 and the first crimping receiving portion 51. Thereby, the predetermined length of the longitudinal direction of the strip | belt-shaped sheet material 1 can be welded. The predetermined length is determined by the length along the longitudinal direction of the first crimping portion 50. The predetermined length can be set as appropriate.

  As shown in FIG. 6B, when the crimping and melting by the first crimping part 50 is finished, the first crimping part 50 moves upward. In accordance with the timing, the spring feed member 41 moves forward, and only one coil spring 2 in the spring guide tube 40 is pushed out. That is, it is pushed out from the tips of the first and second inner shaping plates 30 and 31 simultaneously with being pushed out from the tip of the spring guide tube 40. Thereby, the compressed coil spring 2 is accommodated in a state extending in the width direction in the belt-like sheet material 1 due to its restoring force.

  FIG. 7C is a cross-sectional view showing a state in which the coil spring 2 pushed out from the inner shaping portion and the spring guide cylinder 40 is accommodated in the belt-like sheet material 1. At this time, since the overlapping region 12 is already welded, the cross-sectional shape of the strip-shaped sheet material 1 is maintained despite the restoring force of the coil spring 2. In the overlapping region 12, the first longitudinal end 1a and the second longitudinal end 1b overlap vertically in the horizontal state, so that no protruding portion is formed.

  When one coil spring 2 is pushed out, the second crimping portion 52 moves downward, and the coil spring 2 and the coil spring 2 accommodated adjacent to each other are sandwiched between the second crimping portion 52 and the second crimp receiving portion 53.・ Crimp. Thereby, it heat-welds along the part between the coil spring 2 and the coil spring 2, ie, the width direction of the strip | belt-shaped sheet material 1. FIG. Thereby, the cylindrical bag 10 is formed. That is, the cylindrical bag 10 which is a completely closed space is formed, and one coil spring 2 is accommodated in the internal space.

  The second crimping part 52 moves downward and moves downstream in the transport direction (longitudinal direction forward: x direction) with the belt-like sheet material 1 sandwiched between the second crimping part 52 and the second crimping receiving part 53. . This moving distance is the same as the arrangement pitch of the coil springs 2. Thereby, the whole strip | belt-shaped sheet material 1 is moved downstream by the said pitch (refer FIG. 6C).

  After moving by a predetermined pitch, the second crimping portion 52 moves upward and moves in the opposite direction (x ′ direction) to the transport direction (see FIG. 6D). Thereafter, returning to FIG. 6A again, the same operation is repeated.

<Another embodiment>
In the present embodiment, with respect to the configuration of the overlapping portion 34, the second outer shaping plate 33 is positioned on the first outer shaping plate 32, but either may be up in the vertical relationship.

  The members constituting the inner shaping portion and the outer shaping portion are formed in a plate shape, but the material, processing method, and shape of the members are not limited to this embodiment.

  The region where the first and second longitudinal direction end portions 1a and 1b are overlapped and welded is the central portion in the width direction, but this does not strictly mean the center (1/2), and has a certain width. It is what you have. It may deviate from the exact center position. The area to be welded, the number, etc. can also be determined as appropriate.

DESCRIPTION OF SYMBOLS 1 Strip-shaped sheet material 1a 1st longitudinal direction edge part 1b 2nd longitudinal direction edge part 10 Cylindrical bag 11 Crimping area | region 12 Overlapping area | region 2 Coil spring 30 1st inner shaping plate (inner shaping part)
31 2nd inside shaping plate (inside shaping part)
32 1st outside shaping plate (1st outside shaping part)
33 2nd outside shaping plate (2nd outside shaping part)
34 Overlapping portion 50 First crimping portion 51 First crimping receiving portion

Claims (4)

A continuous pocket coil spring row formed in a row by storing one coil spring in one bag of a continuous cylindrical bag formed in a pocket shape by a belt-like sheet material having air permeability,
The continuous cylindrical bag has a structure in which a coil spring is accommodated along the width direction in a space formed by folding the belt-shaped sheet material from both sides in the width direction, and has a predetermined pitch along the longitudinal direction of the belt-shaped sheet material. And welded along the width direction, and formed by welding the end portions in the longitudinal direction folded the belt-like sheet material,
The longitudinal ends overlap each other in a vertical plane with a first longitudinal end folded from one side in the width direction and a second longitudinal end folded from the other side in the width direction. A continuous pocket coil spring array characterized in that it is welded in a state where the weld position is located at the center in the width direction. A method for producing a continuous pocket coil spring array in which one coil spring is housed in one bag of a continuous cylindrical bag formed into a pocket shape by a belt-like sheet material having air permeability,
Folding the belt-like sheet material from both sides in the width direction to form a space for accommodating a coil spring along the width direction;
Welding the longitudinal ends of the belt-shaped sheet material folded;
A step of sequentially storing coil springs in the space after the welding is completed ;
After accommodating the coil spring, comprising the steps of: welding along said width direction at a predetermined pitch along the longitudinal direction of the belt-like sheet material, a
The longitudinal ends overlap each other in a vertical plane with a first longitudinal end folded from one side in the width direction and a second longitudinal end folded from the other side in the width direction. A method for manufacturing a continuous pocket coil spring array, characterized in that the welding is performed in a wet state. A manufacturing apparatus for manufacturing the continuous pocket coil spring array according to claim 1,
An inner shaping part formed in a quadrilateral cross section;
A first outer shaping portion for folding the belt-like sheet material from one side in the width direction, located on the outer surface side of the inner shaping portion, forming a gap with the outer surface,
A second outer shaping part for folding the belt-like sheet material from the other side in the width direction, located on the outer surface side of the inner shaping part, forming a gap with the outer surface,
The first outer shaping portion and the second outer shaping portion have an overlapping portion having a gap at the center in the width direction,
In the overlapping portion, one of the first longitudinal end and the second longitudinal end is configured to be able to pass through a gap between the overlapping portions, and the first longitudinal end and the second longitudinal The continuous pocket coil spring array manufacturing apparatus, wherein either one of the end portions in the direction is configured to be able to pass below the overlapping portion. Welding means for welding the first longitudinal end and the second longitudinal end is provided on the upper side of the inner shaping portion and downstream of the overlapping portion. The continuous pocket coil spring array manufacturing apparatus according to claim 3.

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