JP7008856B1 - mattress - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mattress with perforations which make it easy to open a plurality of pocket spaces while forming a plurality of pocket spaces without cutting from one piece of cloth. SOLUTION: A mattress having a plurality of pocket coils arranged along a first direction and a second direction orthogonal to each other in a plane perpendicular to the vertical direction, and a coil spring forming each pocket coil. , A plurality of pocket spaces accommodating a plurality of coil springs, the first cloth forming a plurality of pocket spaces arranged in the first direction with one sheet, and one first cloth is a second cloth. Disclosed are mattresses having contiguous perforations in the first direction on either side of a plurality of pocket spaces in a direction. [Selection diagram] FIG. 6

Description

This disclosure relates to mattresses.

A mattress that realizes a pocket coil by accommodating a coil spring in a bag-shaped body that forms a pocket space is known. In this type of mattress, the sides of the bag-shaped bodies prepared separately for each coil spring are glued together, perforations are provided in the waist direction of each of the bag-shaped bodies, and the upper surface of the bag-shaped body is the surface unit. A technique of adhering to the lower surface with an adhesive is known (see, for example, Patent Document 1). In this technique, by pulling the surface unit upward, the perforations of the bag-shaped body are broken and all the upper surfaces of the bag-shaped bodies are opened, so that the coil spring can be easily taken out.

Japanese Unexamined Patent Publication No. 2012-95785

However, in the above-mentioned conventional technique, it is necessary to cut one piece of cloth to form a bag-shaped body separately for each coil spring, so that there is a problem that the manufacturing cost is high. In addition, since the bag-shaped bodies are individually formed, erroneous assembly is likely to occur when arranging a plurality of them. If breakage does not occur at the perforations of some of the bag-shaped bodies due to such misassembly, it may affect the whole and may not be able to break all the perforations at the same time in a desired manner.

On the other hand, when a plurality of pocket spaces are formed without cutting from a single piece of cloth, some of the above-mentioned problems in the case of individually forming a bag-like body can be solved, but the plurality of pocket spaces are made of cloth. Since it is continuous, it becomes difficult to form a perforation that can easily open a plurality of pocket spaces.

Therefore, an object of the present disclosure is to provide a mattress with perforations that make it easy to open a plurality of pocket spaces while forming a plurality of pocket spaces without cutting from a single cloth. do.

On one side, a mattress with multiple pocket coils arranged along first and second directions orthogonal to each other in a plane perpendicular to the vertical direction.
Coil springs that form individual pocket coils,
A plurality of pocket spaces for accommodating the plurality of the coil springs, the first cloth forming the plurality of pocket spaces arranged in the first direction with one sheet, and the like.
One piece of the first cloth provides a mattress having perforations continuous in the first direction on both sides of the plurality of pocket spaces in the second direction.

According to the present disclosure, in a mattress, it is possible to form a plurality of pocket spaces without cutting from a single piece of cloth, and to provide the cloth with perforations that make it easy to open a plurality of pocket spaces. Become.

It is a perspective view which shows the use state of a mattress. It is explanatory drawing of the cross-sectional structure of a mattress, and is the schematic diagram of the cross-sectional structure of a mattress. It is the schematic of the cross-sectional structure of the mattress by another Example. It is a figure which shows typically the arrangement mode of the coil spring in a spring coil layer in the top view. It is explanatory drawing of the non-woven fabric which forms the pocket space in which each of the coil springs is accommodated. FIG. 3 is a plan view of a nonwoven fabric forming a pocket space in which each of a plurality of coil springs in a row is accommodated. It is explanatory drawing of the method of forming a pocket space from a non-woven fabric. It is a side view which extracted three pocket spaces of a plurality of pocket spaces of one row and looked at in the Y direction. It is a side view which extracted three pocket spaces of a plurality of pocket spaces of one row and looked at in the X direction. It is a schematic cross-sectional view along the line AA of FIG. It is a schematic cross-sectional view along the line BB of FIG.

Hereinafter, each embodiment will be described in detail with reference to the accompanying drawings. The dimensional ratios in the drawings are merely examples and are not limited to these, and the shapes and the like in the drawings may be partially exaggerated for convenience of explanation. In the present specification, a piece of cloth such as a non-woven fabric is a piece in a product state, and is a concept including a multi-layer structure as long as the layers are integrated.

FIG. 1 is a perspective view showing a usage state of the mattress 20. In FIG. 1, the X, Y, and Z axes are defined in the right-handed coordinate system. In the following description, the vertical direction (Z direction) is based on the usage state of the mattress 20. The mattress 20 is bedding and is placed and used on the bed frame 7. The mattress 20 can be changed up and down, but the upper and lower sides of the mattress 20 are based on the state shown in FIG. 1 unless otherwise specified. In the case of a mattress that cannot be changed up and down (see, for example, the mattress 20A in FIG. 2A), a logo or the like may be attached to the side of the mattress so that the upper side is clear to the user.

FIG. 2 is an explanatory view of the cross-sectional structure of the mattress 20, and is a schematic view of the cross-sectional structure of the mattress 20. FIG. 3 is a diagram schematically showing an arrangement mode of coil springs 223a and 223b in the spring coil layer 223 in a top view. FIG. 3 defines the X direction (an example of the first direction) and the Y direction (an example of the second direction) similar to those in FIG. 1, where the longitudinal direction of the mattress 20 corresponds to the X direction.

In the example shown in FIG. 2, the mattress 20 has a quilting section 21 (hereinafter, also referred to as “upper quilting section 21” for distinction), a padding section 22, and a quilting section 23 (hereinafter, “lower side” for distinction). It is also referred to as a quilting unit 23 ”).

The upper quilting portion 21 is composed of a surface fabric 211, an artificial cotton 212, a soft urethane 213, and a non-woven fabric 214 from the upper side. The configuration of the upper quilting portion 21 is not limited to this, and other materials may be added or some materials may be omitted.

The surface fabric 211 may be, for example, a knit fabric having antibacterial, deodorant, and mite-proof functions. The surface fabric 211 preferably has a density of 180 g / m ² or more. The surface fabric 211 may have a thickness of, for example, 1 mm.

The artificial cotton 212 may have, for example, a density of about 140 g / m ² . Further, the artificial cotton 212 may have a thickness of, for example, 10 mm.

The soft urethane 213 may have a density of, for example, D28. Further, the soft urethane 213 may have a thickness of, for example, 15 mm.

The non-woven fabric 214 may have a density of, for example, about 40 g / m ² . Further, the nonwoven fabric 214 may have a thickness of, for example, 0.25 mm.

From the upper side, the padding portion 22 includes a non-woven fabric 220, a soft urethane 221, a non-woven fabric 222 (an example of a second cloth), a spring coil layer 223, a non-woven fabric 224 (an example of a second cloth), and a soft urethane 225. It is made of non-woven fabric 226.

The nonwoven fabric 220 may have, for example, a density of about 40 g / m ² . Further, the nonwoven fabric 220 may have a thickness of, for example, 0.25 mm.

The soft urethane 221 may have a density of, for example, D21. Further, the soft urethane 221 may have a thickness of, for example, 20 mm. The upper side of the soft urethane 221 may be formed in an uneven shape. This improves the body pressure dispersion value.

The non-woven fabric 222 may have a density of, for example, about 80 g / m ² . Further, the nonwoven fabric 222 may have a thickness of, for example, 0.25 mm.

In the spring coil layer 223, a plurality of coil springs 223a and 223b each forming a pocket coil are arranged in a parallel arrangement form. Each row of coil springs 223a and 223b extends in the longitudinal direction (X direction) of the mattress 20 and touches each other in the lateral direction (Y direction) of the mattress 20. The number of coil springs 223a and 223b in each row may be the same. In the modified example, a plurality of coil springs 223a may be arranged in an alternating arrangement form.

In this embodiment, as an example, as shown in FIG. 3, when the first to seventh rows are arranged in order from the top in the lateral direction (Y direction), the third to fifth rows are a plurality of coil springs. It is composed of 223a and the other row is composed of a plurality of coil springs 223b. In this way, by using the two types of coil springs 223a and 223b, it is possible to effectively improve the sleeping comfort. However, in the modified example, one or three types of coil springs may be used.

The coil spring 223a forming the spring coil layer 223 has a wire diameter (steel wire diameter) of 1.8 mm and a coil diameter of 62 mm. Further, the coil spring 223a forming the spring coil layer 223 has 5 turns, a coil height of 170 mm as a free length, and 100 mm in a pocket. Each coil spring 223a may be, for example, a lantern type.

Further, the coil spring 223b forming the spring coil layer 223 has a wire diameter (steel wire diameter) of 2.2 mm and a coil diameter of 62 mm. The coil spring 223b forming the spring coil layer 223 has 5.5 turns, a free coil height of 140 mm, and a pocket of 100 mm. Each coil spring 223b may be, for example, a lantern type.

The nonwoven fabric 224 may have, for example, a density of about 80 g / m ² . Further, the nonwoven fabric 224 may have a thickness of, for example, 0.25 mm.

The soft urethane 225 may have a density of, for example, D21. Further, the soft urethane 225 may have a thickness of, for example, 15 mm.

The non-woven fabric 226 may have a density of, for example, about 40 g / m ² . Further, the nonwoven fabric 226 may have a thickness of, for example, 0.25 mm.

The lower quilting portion 23 is composed of a non-woven fabric 231, a soft urethane 232, an artificial cotton 233, and a surface fabric 234 from the upper side. The configuration of the lower quilting portion 23 is not limited to this, and other materials may be added or some materials may be omitted.

The non-woven fabric 231 may have a density of, for example, about 40 g / m ² . Further, the nonwoven fabric 231 may have a thickness of, for example, 0.25 mm.

The soft urethane 232 may have, for example, a density of D28. Further, the soft urethane 232 may have a thickness of, for example, 15 mm.

The artificial cotton 233 may have, for example, a density of about 140 g / m ² . Further, the artificial cotton 233 may have a thickness of, for example, 10 mm.

The surface fabric 234 may be, for example, a knit fabric having antibacterial, deodorant, and mite-proof functions. The surface fabric 234 preferably has a density of 180 g / m ² or more. The surface fabric 234 may have a thickness of, for example, 1 mm.

Although the mattress 20 having a specific configuration is shown in FIG. 2, it is optional as long as it has the spring coil layer 223 and the spring coil layer 223 has the configuration described later. For example, the mattress 20A having the configuration shown in FIG. 2A may be used. In this case, a needle punch 232A or the like is used instead of the soft urethane 232. Such a mattress 20A is suitable for a usage mode in which the mattress 20A cannot be changed up and down (that is, a usage mode in which the positive side in the Z direction is always on the upper side).

Next, the details of the spring coil layer 223 will be described with reference to FIGS. 4 and later. In the following, the configuration of the row related to the coil spring 223a will be described as a representative, but the same is substantially the same for the row related to the coil spring 223b.

FIG. 4 is an explanatory view of a nonwoven fabric 250 (an example of a first cloth) forming a pocket space S1 in which each of the coil springs 223a is accommodated.

As shown in FIG. 4, the nonwoven fabric 250 can take a form of being wound in a roll shape, and when unwound, the perforation 252 is formed by the perforation forming blade 400 (only one is shown in FIG. 4). It is formed. As shown in FIG. 4, two perforations 252 are formed in parallel.

FIG. 5 is a plan view of the nonwoven fabric 250 forming the pocket space S1 in which each of the plurality of coil springs 223a (11 coil springs 223a in FIG. 3) in one row is accommodated. FIG. 5 shows the non-woven fabric 250 in the unfolded state before forming the pocket space S1. In FIG. 5, the alternate long and short dash line L1 represents the center line in the Y direction of the nonwoven fabric 250, and the hatched portions at the upper and lower ends correspond to the welded portions 258 described later. FIG. 6 is an explanatory diagram of a method of forming the pocket space S1 from the nonwoven fabric 250. FIG. 7 is a side view of three pocket spaces S1 out of a plurality of pocket spaces S1 in one row and viewed in the Y direction. FIG. 7 schematically shows the coil spring 223a in the pocket space S1 formed of the nonwoven fabric 250 for the sake of explanation. In FIG. 7 (the same applies to FIGS. 8 and 9 below), each welded portion 256, 258 and the adhesives 80 to 84 are schematically shown by hatching. FIG. 8 is a side view of three rows of pocket spaces S1 adjacent to each other in the Y direction extracted and viewed in the X direction. Also in FIG. 8, for the sake of explanation, the coil spring 223a in the pocket space S1 formed by the nonwoven fabric 250 is schematically shown in perspective. 7 and 8 also show the nonwoven fabrics 222 and 224 on the upper and lower sides of the pocket space S1. 9 is a schematic cross-sectional view taken along line AA of FIG. 7, and FIG. 10 is a schematic cross-sectional view taken along line BB of FIG. 7. The lines BB in FIG. 7 are shown slightly offset from the perforations 252 for the sake of explanation, but are lines along the perforations 252.

As shown in FIG. 4, the nonwoven fabric 250 has two perforations 252 parallel to the X direction. In the unfolded state of the nonwoven fabric 250, the distance between the perforations 252 in the Y direction is larger than the outer diameter of the coil spring 223a.

When forming the coil spring assembly of each row (the assembly consisting of the nonwoven fabric 250 integrated by the welded portions 256 and 258 and the coil spring 223a), one row is formed as schematically shown in FIG. All coil springs 223a are set so that the coil center axis is perpendicular to the surface between the perforations 252 in one non-woven fabric 250. At this time, in each coil spring 223a, the line segment connecting the coil center axes of each coil spring 223a (see the alternate long and short dash line L2 in FIG. 6) is substantially the center (center in the Y direction) between the two perforations 252. As such, it is positioned with respect to one piece of non-woven fabric 250.

From the state in which the nonwoven fabric 250 and the plurality of coil springs 223a are set in this way, the nonwoven fabric 250 is folded back in such a manner that both ends in the Y direction of the nonwoven fabric 250 are overlapped with each other, so that the plurality of coil springs 223a are wrapped by the nonwoven fabric 250. At this time, the two perforations 252 that are continuous in the X direction are located on both sides of the plurality of coil springs 223a in the Y direction.

Then, the welded portions 258 are formed by welding both ends of the nonwoven fabric 250 in the Y direction. That is, the nonwoven fabric 250 according to one row has a welded portion 258 (an example of a second welded portion) for joining the ends to each other on one side of the pocket space S1 related to one row on one side in the Y direction. .. Further, the welded portion 256 (an example of the first welded portion) is formed in a mode of partitioning the pocket space S1 related to the coil springs 223a adjacent to each other in the X direction. In the example shown in FIG. 6, the welded portion 256 is indicated by 256-1 to 256-3 where the welded portion 256 is welded as the welded portion 256 in the nonwoven fabric 250. In this case, one welded portion 256 is formed by welding the paired portions 256-1 to each other, and another one welded portion 256 is formed by welding the paired portions 256-2 to each other. By welding the paired portions 256-3 to each other, another welded portion 256 is formed.

As shown in FIG. 8, the coil spring assemblies of each row formed in this manner (the assembly composed of the nonwoven fabric 250 integrated by the welded portions 256 and 258 and the coil springs 223a) have side portions in the Y direction. Is joined by the adhesive 80. Further, as shown in FIGS. 7 and 8, the coil spring assembly in each row is bonded to the upper nonwoven fabric 222 extending in the XY plane by the adhesive 82, and the lower one extending in the XY plane. It is bonded to the non-woven fabric 224 on the side by the adhesive 84. The non-woven fabric 222 is common to all the coil springs 223a and 223b in one mattress 20, and is adhered (fixed) to the non-woven fabric 250 forming the pocket space S1 in each row. By providing such a non-woven fabric 222, even when a local load (external load) in a direction perpendicular to the surface of the mattress 20 is applied between the pocket spaces S1, local subduction (external load) is performed. It is possible to prevent (getting into the space between each pocket space S1). This also applies to the non-woven fabric 224.

According to this embodiment, since one non-woven fabric 250 is used for each row to form the pocket space S1 of each row, the non-woven fabric 250 is cut and formed for each pocket space S1. There is no need, and productivity is greatly improved.

Further, according to the present embodiment, as described above, the nonwoven fabric 250 according to one row has perforations 252 continuous in the X direction on both sides of each pocket space S1 related to the one row in the Y direction. Further, as shown in FIG. 10, the two perforations 252 are located at substantially the same height, and are continuous in the X direction in a manner of surrounding each coil spring 223a in a top view.

As a result, when the nonwoven fabric 222 is pulled with respect to the spring coil layer 223 in the direction of peeling from the spring coil layer 223 when the mattress 20 is discarded, the nonwoven fabric 222 is adhered to the nonwoven fabric 250 by the adhesive 82. A large force is applied to the perforations 252 of the nonwoven fabric 250. As a result, the perforations 252 in each row are continuously broken. In this way, according to the present embodiment, the upper side of each pocket space S1 can be easily opened with respect to the pocket space S1 in each row.

Further, according to the present embodiment, as described above, in the unfolded state of the nonwoven fabric 250, the distance between the perforations 252 in the Y direction is larger than the outer diameter of the coil spring 223a. Therefore, when the coil spring 223a is housed in the pocket space S1, the perforation 252 is lower than the uppermost winding 2231 of the coil spring 223a and the coil spring, as shown in FIGS. 7 and 8. It is formed at a position above the lowermost winding 2232 of the 223a and biased upward from the axial center of the coil spring 223a. For example, as shown in FIG. 7, the distance Δ1 of the perforation 252 from the upper surface of the pocket space S1 may be within the range of 12-18 mm. As a result, when the nonwoven fabric 222 is pulled in the direction of peeling from the spring coil layer 223 to break the perforations 252, the possibility that the portion of the nonwoven fabric 250 above the perforations 252 is caught by the coil spring 223a is reduced. When the perforation 252 is broken by pulling the non-woven fabric 222 in the direction of peeling from the spring coil layer 223, when the portion of the non-woven fabric 250 above the perforation 252 is caught by the coil spring 223a, the force for pulling the non-woven fabric 222 is applied. A part of the coil spring 223a is applied, and the force required to break the perforation 252 increases by that amount. On the other hand, according to the present embodiment, the perforation 252 can be broken with a relatively low force, and the workability when opening the upper side of each pocket space S1 can be improved.

When the perforation 252 is located below the axial center of the coil spring 223a, when the perforation 252 is broken and the portion of the nonwoven fabric 250 above the perforation 252 is removed together with the nonwoven fabric 222. Further, the portion of the nonwoven fabric 250 above the perforation 252 may be caught by the coil spring 223a. Such catching deteriorates workability. In this respect, according to the present embodiment, such inconvenience is unlikely to occur, and workability when opening the upper side of each pocket space S1 can be improved.

Further, according to the present embodiment, as described above, in the unfolded state of the non-woven fabric 250, the distance between the perforations 252 in the Y direction is larger than the outer diameter of the coil spring 223a. When the side is open, the coil spring 223a can be easily taken out through the upper opening of the pocket space S1. That is, the workability when taking out the coil spring 223a can be improved.

In this embodiment, the welded portion 256 is preferably formed along the vertical direction in a manner of terminating in the vertical direction in front of the perforation 252, as shown in FIG. 7. In this embodiment, the welded portion 256 formed between the two pocket spaces S1 in the X direction is divided into three in the vertical direction, but may be in a larger number. It may be a small number. Further, the welded portion 256 formed between the two pocket spaces S1 in the X direction may be formed in a form continuous in the vertical direction.

In this way, in this embodiment, since the welded portion 256 that partitions the pocket space S1 in the X direction is arranged below the perforation 252, the case where the perforation 252 is included in the welded portion 256 (that is, the welded portion). Workability when breaking the perforation 252 is improved as compared with the case where the perforation 252 is welded to form 256). That is, as shown in FIG. 10, the perforations 252 do not weld to each other in the Y direction, and the force required for continuously breaking the perforations 252 can be appropriately reduced.

Further, in this embodiment, the perforation 252 is located above the welded portion 258 that joins the Y-direction end portions of the nonwoven fabric 250 to each other, as schematically shown in FIG. This improves workability when breaking the perforation 252 as compared with the case where the perforation 252 is included in the welded portion 258 (that is, when the perforation 252 is welded to form the welded portion 258). .. That is, the force required for breaking can be appropriately reduced.

In FIGS. 4 and 4 or later, one non-woven fabric 250 is used for each row of pocket spaces S1 arranged in the X direction, but one non-woven fabric 250 is used for each row of pocket spaces S1 arranged in the Y direction. May be good. In addition, in the description after FIG. 4, such a configuration is a configuration in which the X direction and the Y direction are read as the Y direction and the X direction, respectively. In this case as well, substantially the same effect can be obtained.

Although each embodiment has been described in detail above, the present invention is not limited to a specific embodiment, and various modifications and changes can be made within the scope of the claims. It is also possible to combine all or a plurality of the components of the above-described embodiment.

For example, in the above-described embodiment, the perforation 252 is formed at a position biased upward with respect to the vertical center of the coil springs 223a and 223b. , The coil springs 223a and 223b may be formed at positions biased downward with respect to the center in the vertical direction. In this case, it is possible to realize a configuration in which the perforations are easily broken by pulling from the opposite side (that is, in the direction of peeling the lower nonwoven fabric 224 from the spring coil layer 223). For example, when the mattress 20 can be changed up and down, the perforation 252 is biased upward with respect to the vertical center of the coil springs 223a and 223b, and with respect to the vertical center of the coil springs 223a and 223b. If the mattress 20 is formed at a position biased downward, the user can pull the non-woven fabric 222 or the non-woven fabric 224 to break the upper or lower perforation without being aware of the vertical direction of the mattress 20.

7 Bed frame 20, 20A Mattress 21 Upper quilting part 22 Filling part 23 Lower quilting part 80 Adhesive 82 Adhesive 84 Adhesive 211 Surface fabric 212 Artificial cotton 213 Soft urethane 214 Non-woven fabric 220 Non-woven fabric 221 Soft urethane 222 Non-woven fabric 223 Spring coil layer 223a Coil spring 223b Coil spring 224 Non-woven fabric 225 Soft urethane 226 Non-woven fabric 231 Non-woven fabric 232 Soft urethane 233 Artificial cotton 234 Surface fabric 250 Non-woven fabric 252 Perforation 256 Welding part 258 Welding part 400 Perforation forming blade 2231 Winding 2232 winding

Claims (6)

A mattress having a plurality of pocket coils arranged along a first direction and a second direction orthogonal to each other in a plane perpendicular to the vertical direction.
Coil springs that form individual pocket coils,
A plurality of pocket spaces for accommodating the plurality of the coil springs, the first cloth forming the plurality of pocket spaces arranged in the first direction with one sheet, and the like.
One piece of the first cloth has perforations continuous in the first direction on both sides with respect to the center of the plurality of pocket spaces in the second direction.
The perforation is a mattress formed so as to break by pulling the portion between the two perforations in the first cloth in the second direction upward or downward . The mattress according to claim 1, further comprising a second cloth secured to the portion of the first cloth. The first cloth is used one by one in each row so that the plurality of pocket spaces arranged in the first direction form a plurality of rows in a manner adjacent to each other in the second direction.
The second cloth is fixed to the plurality of first cloths according to the plurality of rows, and is above or below the plurality of pocket spaces related to the plurality of rows, in the first direction and in the second direction. The mattress according to claim 2 , which extends in a plane formed by. The first cloth according to one row is a second weld that joins the ends of the first cloth to the side portions of the plurality of pocket spaces according to the one row on one side in the second direction. Has a part,
The mattress according to claim 3 , wherein the perforation is located above or below the second welded portion. One piece of the first cloth has a first welding portion for partitioning each of the plurality of pocket spaces arranged in the first direction.
The mattress according to any one of claims 1 to 4, wherein the first welded portion is formed along the vertical direction in a manner of terminating in the vertical direction in front of the perforation. The perforation is below the uppermost winding of the coil spring and above the lowermost winding of the coil spring and above or above the axial center of the coil spring. The mattress according to any one of claims 1 to 5, which is formed in a position biased downward.

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