JP6688844B2 - Mattress manufacturing method - Google Patents

Description

The present invention particularly relates to mattress manufacturing method which enables selecting and using one side of the front and back surfaces as required.

  In some mattresses, the cushioning padding housed and sealed in the bag is made of different materials on the upper and lower sides, and the holding surface can be selected by reversing the front and back at the time of use. As an example, FIGS. 8A and 8B show a double-sided futon for both summer and winter of Patent Document 1. In the mattress 1 of the same figure, the cushioning padding housed in the bag of the side cloth 5 is composed of different materials on the upper and lower sides, and when used, it is turned upside down and the holding surface is selected, so that it can be used during cold winter months. It functions as a mattress with excellent heat retention and as a mattress with excellent breathability, moisture absorption, and sweat absorption during the hot summer months.

  The padding is made of a first mattress material layer 2 made of a relatively hard mattress material, and a mattress material material having relatively high heat insulation that is laminated in an overlapping manner on one surface 2a of the first mattress material layer. The second mattress material layer 3 and the third mattress material layer 4, which is a mattress material material having relatively high air permeability and moisture absorption, which is laminated on the other surface 2b of the first mattress material layer. Further, in the embodiment, polyester or polyurethane is used for the first mattress material layer 2, far infrared treatment containing zirconium silicate ceramics is used for the second mattress material layer 3, and the third mattress material is used. It is described that hemp or sweat absorbent polyester is used for the fabric layer. Reference numeral 7 indicates a quilt processing line.

JP, 10-75852, A

  By the way, in the field of nursing care and general household use, for example, for the purpose of keeping a bad physical condition such as a backache and maintaining a proper sleeping posture, a mattress type that is relatively hard is replaced with a softer fiber cushion type as a padding for the mattress, Conversely, it is also common to replace fiber cushion systems with mattress systems. In view of such a background, the present inventors have studied in order to obtain a mattress that can be used in an optimum mode by selecting a holding surface according to the physical condition such as back pain in addition to the holding characteristics and appearance characteristics of the front and back surfaces. As a result of being accumulated, the present invention has been achieved.

An object of the present invention, as manufacturing process of mattress that have enabled by selecting the front and back, excellent in retention properties and appearance properties, the selective ease or to choose which side of the front and back surfaces (easy determination It is to provide products that are excellent in anti-steaming and mites prevention. Other purposes will be made clear in the following description.

To achieve the above object, the invention of claim 1 is specified with reference to the drawings. The cushioning padding (5) housed and sealed inside the bag is made of different materials on the upper and lower sides, and when used, the front and back In the method for manufacturing a mattress which can be inverted to select the holding surface, a step of forming an outer surface side fiber part for forming the cotton fiber part (8a) for covering the outer surface of the padding (5) with cotton fibers and having substantially the same size as that of the mattress. And a mattress arranging step of arranging a foam mattress (6) which is slightly smaller than the cotton fiber portion on the upper surface of the outer cotton fiber portion (8a), the outer cotton fiber portion (8a) and the foam mattress (6). The step of forming the cotton fiber portion (8c) for surrounding coating so as to fill the step (S) formed between the above) and the mixed fiber in which the chemical fiber is mixed with the cotton fiber, the foam mattress (6) Inside and outside Among them, it is characterized in that to produce at least through the fiber cushion body forming step of fibrous cushion body (7) laminated on the inner surface side which is an outer surface facing that placing the outer surface side cotton fiber unit.

In the above invention, "cotton fiber" means pure cotton or 100% cotton fiber. The "fiber cushion body" is a cushion body formed of a mixed fiber in which a cotton fiber which is a natural fiber is mixed with a chemical fiber such as polyester.

  As the mixed fibers, it is preferable to mix cotton fibers with about 30% of chemical fibers such as polyester. That is, cotton fibers are particularly excellent in breathability, moisture release and water absorption, and are also less susceptible to static electricity. Chemical fibers are particularly low in cost and lightweight, but are inferior in breathability or moisture release to cotton, and easily attract static electricity to attract dust and mite antigens. The mixing ratio will be set by considering these properties. In addition, the side fabric of the present invention is made of 100% cotton or a material equivalent to or similar to it from the viewpoint of preventing ticks.

  The "foam mattress" is a urethane foam or a foamed molded product similar thereto. This name is used to exclude the types called mattresses such as spring mattresses and lock mattresses. The "outer surface of the foam mattress" is, for example, the surface disposed on the lower side in the state of the mattress of Figs. 1 and 2, that is, the surface away from the fiber cushion body. The "inner surface of the foam mattress" is, for example, the surface arranged on the upper side in the state of the mattress of Figs. 1 and 2, that is, the surface close to the fiber cushion body. The upper cloth and the lower cloth constituting the inner bag and the outer bag are the names as drawn on the drawing, because the top and bottom are turned upside down when the mattress is turned upside down.

Above inventions, it is preferable to be further embodied as follows.

(A), Oite to claim 1, next to the fiber cushion body forming step, and said fibrous cushion body of the outer surface and the outer surface coating cotton fibers portion so as to cover the circumferential side surface and the surrounding coating cotton fibers unit It is a structure that undergoes an outer surface / surrounding side fiber portion forming step (claim 2) .
(B), Oite to claim 1 or 2, while accommodating the padding in Nakabukuro, corresponding to the bent portion when fold up mattress to the padding and the in bag as quilting process to three-fold state Nica Quilting portions, each of which is formed of a linear sewing line extending in the width direction, are provided at a certain position, and then the outer peripheral connecting portion of the inner bag is connected to the outer peripheral portion of the inner bag. It is configured to be stored in a state in which it is connected by sewing to the first side (claim 3) .

According to the first aspect of the invention, the cushioning padding is made of different materials on the upper and lower sides, and is superior in the following points as a method of manufacturing a mattress in which the holding surface can be selected by reversing the front and back during use.

According to the present invention, the mattress of the mattress is manufactured through the outer surface side fiber part forming step, the mattress arranging step, the peripheral side fiber part forming step, and the fiber cushion body forming step, so that the mattress can be manufactured by a normal futon manufacturing facility. In the invention of claim 2, after the fiber cushion body forming step, the outer surface / surrounding side fiber portion forming step is performed.

According to a third aspect of the present invention, in the first or second aspect, after the stuffing is accommodated in the inner bag, a quilting portion composed of a straight sewing line is provided at two locations corresponding to the folding portion, and then the inner bag is placed inside. By sewing the outer peripheral connecting portion of the inner bag and the inner peripheral connecting portion of the outer bag, the bag can be manufactured as a mattress which is particularly excellent in appearance characteristics and mites.

In the mattress produced by the manufacturing method of claim 1, one of the upper side and the lower side of the padding is a foam mattress such as polyurethane and the other is a fiber cushion body. Therefore, the holding and feel characteristics of the mattress are clearly shown on the front and back. Differently, as a result, the user is able to make a quick decision without hesitation about the desired holding surface.

In addition, in the mattress to be manufactured, the fiber cushion body contains cotton fibers and chemical fibers such as polyester, so the material cost can be reduced as a stuffing, the weight can be easily reduced, and good breathability can be maintained as it is. Therefore, it is possible to prevent stuffiness, and suppress the generation of mold, mites, and spots caused by sweat. This point becomes more certain because the foam mattress described later is covered with the outer surface coating cotton fiber portion and the peripheral coating cotton fiber portion.

Further, in the mattress produced, at least one of the inner and outer surfaces and the peripheral side surfaces of the foam mattress covers the outer surface of the mattress with the cotton fiber portion for covering the outer surface, and covers the peripheral side surface of the mattress with the cotton fiber portion for surrounding coating. In this configuration, in addition to the above-mentioned advantages, first, in a state where the padding is stored in the inner bag, the shape of the mattress on the peripheral side of the mattress is the fiber cushion due to the presence of the cotton fiber portion for surrounding coating, as inferred from FIG. Elastic contraction to the same extent as the body, so that good appearance characteristics can be maintained even when the filling is made of different materials on the upper and lower sides. In addition, since the foam mattress contacts the inner bag through the cotton fiber part for outer surface coating and the cotton fiber part for surrounding coating, generation of static electricity and accompanying entry of mite antigen (mite feces, carcasses, molting shells, eggs, etc.) It suppresses, and makes it possible to block or absorb the water droplets of dew condensation with cotton that easily evaporates.

The mattress produced by the manufacturing method according to claim 2 has a cotton fiber portion for covering the outer surface covering the outer surface of the fiber cushion body and a cotton fiber portion for covering the peripheral side surface as shown in FIG. Therefore, the fiber cushion body more reliably suppresses the generation of static electricity caused by the chemical fibers mixed with cotton fibers and the accompanying invasion of mite antigen, and blocks or absorbs the water droplets of dew condensation with cotton that easily evaporates. to enable.

In the mattress produced by the manufacturing method according to claim 3, as shown in Fig. 2 (c), the padding is covered with the double structure of the inner bag and the outer bag as shown in Fig. 2 (a), and the linear sewing of the quilting portion is performed. As shown in (b), the line is applied to the stuffing and the inner bag excluding the outer bag, and the inner bag and the outer bag are integrated as shown in (c), which is an excellent measure against ticks. That is, in this structure, the entry and exit of the mite antigen is prevented by the double bag. At the same time, since the sewing line of the quilting part is provided excluding the outer bag, the outer bag has no quilt needle hole or seam hole, thereby preventing the mites antigen from entering or leaving the bag. At the same time, since the inner bag and the outer bag sew the outer peripheral connecting portion of the inner bag to the inner peripheral connecting portion of the outer bag, for example, by preventing the inner bag (stuffing) from being displaced and integrating the constituent members, each surface side It is possible to reliably maintain the retention characteristics and the touch characteristics of the. Furthermore, the stress when folding the mattress is not applied to the sewing line that divides the inside of the bag, and the expansion of needle holes and stitch holes in the sewing line is prevented, and the resulting entry and exit of the mite antigen into and out of the bag. Can be prevented (refer to Japanese Patent No. 3844131 for this point).

Further, in the present invention, the sewing line of the quilting part is not directly visible from the outside of the outer bag, but in reality, it can be seen through the outer bag thinly as shown in FIG. 1 (a), or as the mattress as shown in FIG. 2 (b). When folded multiple times, the corresponding parts of the outer bag are marked with a streak, which gives us a novel appearance with usability. In the use of a nursing care facility, for example, even a person with a developmental disorder in the brain can easily recognize the foldable point and the foldable position. Further, the inner bag and the outer bag are integrated in a state where the outer peripheral connecting portion of the inner bag is sewn to the inner peripheral connecting portion of the outer bag. Therefore, as the mattress, the sewn portion does not appear on the outer surface side of the outer bag at all, and in this respect, the appearance is simple and novel.

FIG. 1 is a schematic view of a mattress of the present invention, (a) is a top view, (b) is a side view, and (c) is a side view showing the mattress folded in three. 1A is a cross-sectional view of an essential part of FIG. 1A, in which FIG. 1A is an enlarged schematic sectional view taken along line AA, FIG. 1B is an enlarged schematic view of portion X, and FIG. . The padding of the said mattress is shown, (a) is the top view which fractured | ruptured a part of padding, (b) is the CC line enlarged schematic sectional view of the same (a), (c) is the C- of the same (a). It is a C line expansion schematic cross section. FIG. 6B is a schematic top view showing the state where the filling is being stored in the inner bag, and FIG. 7B is a schematic top view showing the state where the filling is stored in the inner bag and then subjected to the quilting process. 4A is an enlarged schematic sectional view taken along line EE of FIG. 4B, and FIG. 4B is an enlarged schematic sectional view taken along line FF of FIG. 4B. It is the modification 1 of the said form, (a) is a schematic top view shown in the same aspect as FIG.4 (a), (b) is an E1-E1 line expanded schematic cross section of the same (a), (c) is a figure It is a schematic cross section corresponding to 3 (c). It is the modification 2 of the said form, (a) is a schematic top view shown in the same aspect as FIG.4 (a), (b) is an E2-E2 line expanded schematic cross section of the same (a), (c) is a figure. It is a schematic cross section corresponding to 3 (c). (A) And (b) is a figure corresponding to FIG. 1 and FIG. 2 of patent document 1. FIG.

  Embodiments of the present invention will be described below with reference to the drawings. In this description, the structure of the mattress shown in FIG. 1 to FIG. 5, which is an example of the embodiment, the modification example 1 and the modification example 2 are described in detail, and then the method of manufacturing the mattress is referred to.

(Structure) In FIG. 1 to FIG. 5, in the mattress 1, the cushioning padding 5 housed and sealed in the bags (2, 3) is made of different materials on the upper and lower sides, and is turned upside down when used. It is the same as the conventional one in that the holding surface can be selected and it is assumed that it will be folded in three when not in use. As a device, the padding 5 has a foam mattress 6 made of polyurethane or the like on one of the upper side and the lower side and a fiber cushion body 7 on the other side, and the foam mattress 6 covers at least the outer surface of the inner and outer surfaces and the peripheral side surfaces. It has a cotton fiber portion 8a for covering the outer surface and a cotton fiber portion 8c for covering the peripheral side surface 6a. The side cloth or bag structure is stored in a state where the filling 5 is stored in the inner bag 2 and the inner bag 2 is connected to the outer bag 3 from the outer peripheral connecting portion 20 of the inner bag to the inner peripheral connecting portion 30 of the outer bag. It is, also, has a quilted 9 padding 5 and Nakabukuro 2 are provided corresponding to the bent portion of the Nica plants when fold up mattress 1 to a three-fold state. Below, these details will be clarified.

  First, the basis of the padding 5 is a two-layer laminated body of a foam mattress 6 such as urethane foam and a fiber cushion body 7 in which cotton fibers and chemical fibers are mixed. The foam mattress 6 is, for example, polyurethane or urethane foam. This urethane foam is formed by mixing a foaming agent, a foam stabilizer, a catalyst, a colorant, etc., which are mainly composed of polyol and polyisocyanate, and foam-molding them. A soft polyurethane foam that has open cells and is soft and has a restoring property. Is preferred.

The foam mattress 6 used has physical properties such as a density of about 16.5 to 24 kg / m ³ , a hardness (25%) of about 100 to 125 N, and a hardness (40%) of about 105 to 140 N, It is preferable that the tensile strength is about 65 to 80 kPa, the impact resilience is about 33 to 39%, and the elongation is about 120 to 150%. As an example of the sensation test, a density of about 16.5 kg / m ³ is suitable for softening, a density of about 24 kg / m ³ is suitable for hardening, and a density of about 20 kg / m ³ is suitable. It was suitable as an intermediate or standard product.

  The thickness L1 of the foam mattress 6 is preferably about 10 to 25 mm in consideration of the total weight of the mattress. The total weight of the mattress varies considerably between adults and children. For adults, the commercially available mattress is about 7 kg, but the mattress of the present invention is designed to be lighter at about 6 kg.

  Further, in the foam mattress 6, of the inner and outer surfaces and the peripheral side surfaces, the outer surface is covered with the outer surface covering cotton fiber portion 8a, the inner surface is covered with the inner surface covering cotton fiber portion 8b, and the peripheral side surface 6a is covered around with the cotton fiber. It is covered with a cotton fiber portion 8c. Out of these, the outer surface coating cotton fiber portion 8a and the inner surface coating cotton fiber portion 8b are formed to be considerably thinner than the thickness L1 of the foam mattress 6 (for example, less than half of L1), and one round from the foam mattress 6. Widely formed. The surrounding coating cotton fiber portion 8c has a thickness that fills the step S formed between the outer surface coating cotton fiber portion 8a and the foam mattress 6. The cotton fiber is made of 100% cotton, and is superior to the fiber cushion body 7 in breathability, moisture release, and water absorption, and static electricity is hard to occur.

  The fiber cushion body 7 is formed of a mixed fiber obtained by mixing a cotton fiber with a chemical fiber such as polyester to have the same size as the outer surface coating cotton fiber portion 8a and the inner surface coating cotton fiber portion 8b. Here, as the mixed fiber used for the fiber cushion body 7, it is preferable to mix cotton fiber with about 30% of chemical fiber such as polyester. The reason is that the advantages of cotton fiber and the advantages of chemical fiber are combined as described above. Considering the total weight of the mattress 1, the thickness is preferably about 15 to 30 mm.

  First, as shown in FIG. 4, the inner bag 2 has one side on the longitudinal direction and one side on the left and right sides in a state where the upper cloth 2a and the lower cloth 2b cut into a rectangular shape having a predetermined size (wider than the mattress) are stacked. Are connected by the sewing line 10 and are formed in a bag shape, and have an outer peripheral connecting portion 2a formed between the sewing line 10 and the cloth end. The upper and lower cloths 2a and 2b are made of 100% cotton. The width of the peripheral connecting portion 2a is about 10 to 25 mm. The padding 5 is inserted into the inner bag 2 through the opening on one end side and stored therein, and then the opening on one end side is sealed by the sewing line 10.

The stuffing 5 and the inner bag 2 are integrated by a quilting process. In this process, it provided Nica office corresponding to the bent portion when folded to a three-fold state mattress as shown in FIG. 4 (b), 2 pieces of straight sewing line 9a, each extending in the width direction, 9a And a cross-shaped quilting portion 9b provided by sewn stitches at a plurality of positions. Two quilting parts 9b are provided between the quilting parts 9 and between the quilting parts 9 and one end side and the other end side in the longitudinal direction. The same (b) is the inner bag 2 thus completed. In addition, each sewing line 10 is processed so as to prevent the mite antigen from passing through by reducing the stitch interval or reverse stitching. In this respect, the sewing lines 11 to 13 described later are also the same.

  The outer bag 3 has an inner peripheral connecting portion 30 which is formed when the upper cloth 3a and the lower cloth 3b are formed into a bag shape and which is connected and fixed to the peripheral connecting portion 2a when the inner bag 2 is housed in the bag. is doing. The upper and lower cloths 3a and 3b are made of 100% cotton. A plain weave is generally used as this weave, but a satin weave is preferable when it is desired to impart a smooth touch. The upper cloth 3a and the lower cloth 3b are in a state where the edge portions are sewn together at the first sewing line 11 and folded back to the outside at the first sewing line 11. It is sewn by the second sewing line 12 along the folded portion where four sheets are overlapped by the folding. Therefore, the folded-back portion has a relatively thick flat shape in which four sheets are overlapped with each other in the state of being sewn on the second sewing line 12, and hides the first sewing line 11 inwardly invisible. On the other hand, the peripheral connecting portion 30 is formed on the terminal side of the edge portion, and is in a state of being projected into the bag from the place where four sheets are stacked. Further, the peripheral connecting portion 30 is swingable because the base portion is positionally regulated by the second sewing line 12 and the tip is on the end side of the edge portion.

  In the above structure, the inner bag 2 containing the padding 5 is housed in the outer bag 6, and the outer peripheral connecting portion 20 of the inner bag is integrated with the inner peripheral connecting portion 30 of the outer bag by the sewing line 13. ing. Therefore, the peripheral connecting portion 20 and the peripheral connecting portion 30 are connected by the third sewing line 13 and are accommodated in the bag of the outer bag 3 and the corresponding portion of the inner bag 2. In the structure described above, a dedicated member is not required even when the inner bag 2 and the outer bag 3 are fixed at the peripheral portion, and even when the mattress 1 is repeatedly folded, stress causes the swing displacement of the peripheral connection portions 20 and 30. And the sewing lines 10, 11, 12 are not excessively loaded.

(Modifications) FIGS. 6 and 7 show two modifications 1 and 2 in which the structure of the above-mentioned mattress is partially modified, and each (a) is a schematic top view shown in the same mode as FIG. 4 (a). (B) is an enlarged schematic sectional view of the E1-E1 line or E2-E2 line of (a), and each (c) is a schematic sectional view corresponding to FIG. 3 (c). In Modifications 1 and 2, the padding 5 and the quilting portion 9 are modified as compared with the embodiment. In the description of each modified example, the same reference numerals are given to the same portions or parts as those of the embodiment, and the changed points will be described in detail while avoiding duplicated description as much as possible.

  In the modified example 1, as shown in FIG. 6, the cotton fiber portion 8b for covering the inner surface of the foam mattress 6 that constitutes the padding 5 is omitted, and the outer surface where the fiber cushion body 7 covers the outer surface. It is modified in that it has a covering cotton fiber portion 8d and a surrounding covering cotton fiber portion 8e covering the peripheral side surface. In this configuration, the outer surface-covering cotton fiber portion 8d and the peripheral-covering cotton fiber portion 8e generate static electricity due to the chemical fibers mixed with the cotton fibers constituting the fiber cushion body 7, and the mite antigen is sucked and invaded therewith. More reliably, and the water droplets of dew condensation can be blocked or absorbed with cotton that easily evaporates. Further, in the quilt process, the quilting portion 9 in the width direction is changed in that it is constituted by a set of three sewing lines 9a. In the quilting part 9, since three sewn lines 9a are configured as a set in the folding operation of the mattress, the quilting part 9 functions to facilitate folding to some extent.

  In the second modification, as shown in FIG. 7, the cotton fiber portion 8b for covering the inner surface of the foam mattress 6 which constitutes the padding 5 is omitted. Moreover, the quilting part 9 of the modified example 2 is composed of a single sewing line 9a. That is, the mattress of Modification 2 is simplified as compared with the form example and Modification 1.

(Manufacturing Method) Next, an example of a method of manufacturing a mattress in which the above-mentioned padding is made of different materials on the upper and lower sides and the holding surface can be selected by reversing the front and back during use will be described with reference to the drawings. In this manufacturing method, an example of manufacturing the mattress shown in FIG. 6 will be described using a padding production line and a bag assembly line that stores and seals the padding in an inner bag and an outer bag.

  In the padding production line, an outer surface side fiber portion forming step for forming the outer surface covering cotton fiber portion 8a, a mattress arranging step for arranging the foam mattress 6 on the outer surface side cotton fiber portion 8a, and a peripheral covering cotton portion for filling the step S The padding 5 is produced through a peripheral side fiber part forming step of forming the fiber part 8c, a fiber cushion body forming step of stacking and forming the fiber cushion body 7 with mixed fibers, and an outer surface / peripheral side fiber part forming step of the fiber cushion body 7. To do.

  Here, in the outer surface side fiber portion forming step, a rectangular plate-shaped outer surface covering cotton fiber portion 8a having substantially the same size as that of the mattress is made of cotton fibers prepared in advance. In the mattress arranging step, the foam mattress 6, which is a soft urethane foam cut into a size smaller than the cotton fiber portion 8a, is positioned and arranged on the upper surface of the cotton fiber portion 8a. In the peripheral fiber portion forming step, the peripheral covering cotton fiber portion 8c is manufactured so as to fill the step S formed between the cotton fiber portion 8a and the foam mattress 6 with the cotton fiber. In the case of the stuffing shown in FIG. 3, the upper surface-covering cotton fiber portion 8b is made of cotton fiber on the upper surfaces of the cotton fiber portion 8a and the cotton fiber portion 8c.

  Then, in the fiber cushion body forming step, the inner surface of the foam mattress 6 (on the cotton fiber portion 8b and the cotton fiber portion 8c in the case of the stuffing of FIG. 3) is formed by the mixed fiber obtained by mixing the cotton fiber with the chemical fiber such as polyester. The fiber cushion body 7 is laminated and formed. In the outer surface / surrounding side fiber portion forming step, the outer surface covering cotton fiber portion 8d and the surrounding covering cotton fiber portion 8e are produced so as to cover the outer surface and the peripheral side surface of the fiber cushion body 7.

  In the bag assembly line, the inner bag manufacturing process, the filling storage process, the quilting process, the outer bag manufacturing process, the integrated process of fixing the quilted inner bag to the outer bag, the inner bag covered with the outer bag. The mattress 1 is completed through a bag filling process for sealing the entrance.

  Here, in the inner bag manufacturing process, the side fabric that has been cut into the design size, that is, the upper and lower cloths 2a and 2b for the inner bag is formed into a bag shape by sewing, leaving the batting insertion inlet. In this sewing, the peripheral edge portions of the upper and lower cloths 2a and 2b are overlapped with each other and the sewing line 10 is located inside the terminal to form the outer peripheral connection portion 20 described above. In the stuffing storage step, the stuffing 5 is inserted into the inner bag 2 through the inlet as shown in FIG. After that, the entrance is closed by a joint stitch similar to the sewing line 10. In the quilting process, as shown in FIG. 6 (a), a quilting portion 9 composed of a plurality of linear sewing lines 9a extending in the width direction by a sewing machine of a dedicated machine, and a cross-shaped quilting portion 9b at a plurality of locations by sewn stitches. Are provided, and the padding 5 and the inner bag 2 are integrated to prevent relative displacement.

  In the outer bag manufacturing process, the side fabric that has been cut to the design size, that is, the upper and lower cloths 3a and 3b, is sewn into a bag shape with an open inlet. In this sewing, as can be inferred from FIG. 2 (c), the upper and lower cloths 3a and 3b are turned over (the inside is laid on the outer surface when the futon is used) and the peripheral edge portions are overlapped with each other, and the first sewing line 11 Are sewn together so that is located inside the terminal. After sewing, the bag-like inner and outer surfaces are reversed using the inlet (the outer surface is used as the outer surface when using a futon), and four peripheral portions are sewn. In this sewing, the peripheral connecting portion 30, which is the terminal side of the edge portion protruding into the bag, is defined by the second sewing line 12 that is sewn together except for the entrance.

  In the integration step, the upper and lower cloths 3a, 3b are turned to the inside-outer surface of the bag-like inner surface, that is, turned inside out again, using the inlet. In this state, the peripheral connecting portion 30 projects around the inside of the bag. Next, the peripheral connecting portion 20 is placed on the positioning arrangement, that is, the peripheral connecting portion 30, on the outer bag 3 in which the completed inner bag 2 is turned inside out. After that, the peripheral connecting portion 20 and the peripheral connecting portion 30 are integrated by the third sewing line 13 which is sewn together except the entrance.

  In the bag filling step, the bag-like inner and outer surfaces are reversed by using the inlet so that the integrated inner bag 2 can be put inside the outer bag 3 (the outer surface is the outer surface when the mattress is used), and the outer bag 3 The inner bag 2 is covered with. After that, the corresponding portion is sewn and sealed so as to close the inlet. In this sewing, it is preferable that the entrance corresponding portion is sewn together along the second sewing line 12 in order to make the appearance look indistinguishable from the second sewing line 12. As described above, the mattress 1 can be relatively easily manufactured by the existing sewing equipment. For details of the bag assembling line, refer to Japanese Patent No. 3844131.

  It should be noted that the present invention is not limited to the above-described modes and modifications, and only needs to have the requirements specified in the claims, and the details can be variously changed based on this. As an example thereof, the cruciform quilting part may be omitted entirely or partially, or an inner bag and an outer bag may be joined and integrated by an adhesive applied along the quilting part (Japanese Patent Publication No. 7-32735). That is. Further, as a manufacturing method, for example, heat treatment is performed when the filling is stored in the inner bag in the filling storage step, or the mattress produced in the bag filling step is subjected to a drying treatment, etc., which are added as necessary. Is.

1 .... Mattress (1A and 1C are one side part, 1B is middle part)
2 .... Inner bag (2a is upper cloth, 2b is lower cloth, 20 is outer peripheral connecting portion)
3 ... Outer bag (3a is upper cloth, 3b is lower cloth, 30 is inner peripheral connecting portion)
5 ... Filling 6 ... Foam mattress (6a is the surrounding side)
7 ... Fiber cushion body (7a is the peripheral side surface)
8a ... ・ Cotton fiber portion for coating the outer surface 8b ・ ・ ・ ・ ・ ・ Cotton fiber portion for coating the inner surface
8c ... Cotton fiber part for surrounding coating
9 .... Quilting part (9a is a straight sewing line)
10 to 13 ... Sewing line (sewing part)
S ...

Claims (3)

In the method of manufacturing a mattress, the cushioning padding that is housed and sealed inside the bag is composed of different materials on the upper and lower sides, and the holding surface can be selected by reversing the front and back during use,
The stuffing,
An outer surface side fiber part forming step for making a cotton fiber part for outer surface coating having substantially the same size as the mattress,
A mattress arranging step of arranging a foam mattress that is slightly smaller than the cotton fiber portion on the upper surface of the outer surface coating cotton fiber portion,
A peripheral fiber portion forming step of forming a peripheral coating cotton fiber portion so as to fill a step formed between the outer surface coating cotton fiber portion and the foam mattress,
A fiber cushion in which a fiber cushion body is laminated and formed on the inner surface of the foam mattress, which is opposed to the outer surface on which the outer surface-covering cotton fiber portion is disposed, by using a mixed fiber in which a chemical fiber is mixed with a cotton fiber. A method for producing a mattress, which is produced through at least a body forming step. After the fiber cushion body forming step, an outer surface / surrounding side fiber portion forming step of forming an outer surface coating cotton fiber portion and a peripheral coating cotton fiber portion so as to cover the outer surface and the peripheral side surface of the fiber cushion body is performed. The method of manufacturing the mattress according to claim 1, wherein   In a state where the stuffing is stored in the inner bag, the linear sewing line is located at two positions corresponding to the bending portions when the mattress is folded into three folds with respect to the stuffing and the inner bag, each extending in the width direction. 7. A quilting part is provided, and then the inner bag is stored in the outer bag in a state in which the outer peripheral connecting portion of the inner bag is connected to the inner peripheral connecting portion of the outer bag by sewing. The method for producing the mattress according to 1 or 2.

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