JPH05103712A - Futon and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a futon (Japanese-style bedding) allowing the substantial improvement of workability and productivity for manufacture with a simple structure, compared with a conventional structure. CONSTITUTION:Front and reverse cloth side sections are formed to a sack shape, and the inside thereof is divided to have a plurality of rectangular cells 4 of the predetermined equal breadth in the same direction, thereby making a side bag 1. Also, a bag material 6 of gas permeable cloth so formed as to have an approximately rectangular parallelopiped shape is filled with fillers 3 such as feathers and sealed, thereby making a plurality of small sack bodies 2 of both the predetermined breadth and approximately identical breadth. The sack bodies 2 are housed into each space 4 in a single row and tier, thereby forming a futon. According to this construction, the cells 4 can further be divided to unify the state of the fillers 3 for a secondary purpose over a long period, or desired different hot insulation performance can be set for each section of the futon. Thus, a futon of improved service performance can be provided at proper cost.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a futon and a method for manufacturing the same, and in particular, a futon having a structure in which a large number of small sections are formed by dividing the interior of the futon in order to prevent the filler such as feathers from moving inside. And a manufacturing method thereof.

[0002]

2. Description of the Related Art A futon is generally made by filling the inside of the side material with a filling material. Futon cotton or down is used for this filling. By the way, the daily use of the futon with a grated grate may cause the filling material to not be evenly distributed inside the lateral ground, which may make it uncomfortable to use. Consideration is generally given to prevent this. It is also possible to sew the side material from the front side after filling without forming compartments to form small compartments (so-called quilting), but especially when the filler is feathers, its characteristics and texture are utilized. For this reason, a method is widely used in which a large number of small compartments having a sufficient volume are formed in the lateral area and each small compartment is sequentially filled with an appropriate amount of feathers.

Hereinafter, a conventional duvet and a method for manufacturing the same will be illustrated by taking a duvet as an example. 7 and 8 show a conventional duvet (feather duvet). In the duvet 20 shown in the figure, the side fabrics 1a and 1b on the front and back sides are formed into a bag shape, and a partition cloth 5 having a predetermined width (the thickness of the futon) is formed between them (in the figure, two partition cloths form an integral partition cloth). 1) on the front and back sides in a matrix form
a, 1b, and is inserted into the inside of the bag, and the peripheral portions of the lateral sides 1a, 1b are covered with edge cloth 1e and attached, and sealed by appropriate means such as a large number of small compartments 9 (9 ₁₁ , 9 ₁₂₎ inside the futon. , ~, 9
₄₆ ) is formed and each of the small compartments 9 is filled with the feather 3 as a filling material, and then the remaining opening portion (filling port) is sealed.

In order to attach the partition wall cloth 5 to the inner surfaces of the front and back side cloths 1a, 1b, the side cloths 1a, 1b are bonded to the partition cloth 5, and the partition cloth 5 is bonded along the substantially central portion in the width direction of the bonding surface. The partition cloth 5 having the extending portion, which is fixed in advance by a strong attachment method, is adhered to the predetermined adhesive portion of the side materials 1a and 1b. The partition cloth 5 has a structure in which a pair of strips are combined, and each strip is formed by fixing two portions, that is, a base fabric and an extending fabric.

A non-woven fabric is used for the partition cloth 5 in consideration of air permeability. The side end surface (adhesive surface 5b) of the strip material forming the partition cloth 5 is previously coated or impregnated with a thermosetting adhesive material for adhering to the side material, and dust or the like adheres before the adhering process. It is covered with a protective tape to prevent the adhesive performance from deteriorating. Such strip-shaped partition cloths 5 are attached in a grid pattern between the front and back side walls respectively to form a large number of small compartments 9 inside the side ground. The cloth 5 is provided with filling holes 5c each having a suitable shape such as a round hole in advance at a position substantially aligned with the arrangement direction. The filling hole 5c is provided to sequentially pass through the pipe P of the filling tool.

The partition cloth 5 prepared in such a form is adhered and fixed to the lateral surfaces 1a and 1b by the adhesive surface 5b. For the adhesion, the protective tape is removed, the adhesive surface 5b is overlaid on the inner surface predetermined joining portion 1c of the front side fabric 1a, and then heat is applied by an iron or a thermocompression bonding machine, and then cooled (the heat source is removed and left) and the adhesive surface 5b The base bonding portion 1c is heat-bonded. Similarly, the adhesive surface 5b of the strip material (partition wall cloth) is also overlapped on the inner surface predetermined joint portion 1c 'of the back side cloth 1b corresponding to the front side cloth, and then the both are heat bonded. An iron may be used for this thermocompression bonding work, but in the manufacture of the futon, since the bonding portion 5b is generally long, it is necessary to use a thermocompression bonding machine having a configuration similar to that of a press machine from the viewpoint of labor saving and high quality of products. There are many.

Thereafter, one end of the duvet 20, for example, 20
From the side a, the free ends of the partition cloth (band material) are sewn and fixed to the opposing ends 20b sequentially in the longitudinal direction and then in the lateral direction, and finally, the peripheral portions of the two sides 1a and 1b are fixed to form a bag. To do.
At this time, the positions corresponding to the filling holes on the one end side 20b of the peripheral edge portion are not sealed but opened as filling ports 20c. In this way, it is partitioned by the partition cloth 5 and each small compartment (9
₁₁ , 9 ₁₂ , ..., 9 ₄₆ ) are formed. At the same time, the filling holes 5c and the filling ports 20c are sequentially located at the partition cloth positions which are substantially aligned in the direction in which they are arranged in the partition walls of the small compartments that are aligned in a vertical or horizontal row.

[0008] Next, the respective small compartment (9 _11, 9 _12, -,
9 ₄₆ ) The feathers 3 which are the fillers are blown into and filled with compressed air. For this purpose, a tubular filling pipe P of a filling machine (not shown) is inserted from the filling port 20c through each filling hole 5c to the innermost small compartment (for example, 9 ₁₁ ), and the feather 3 is inserted. Blow with compressed air the small compartment 9
Fill ₁₁ with 3. Next, the small compartment 9 _{12 in} the front and the small compartment 9 _{13 in the} front are sequentially arranged in a row in each small compartment (9 ₁₁ ,
9 ₁₂ , ..., 9 ₁₆ ) All are filled with feather 3 in an appropriate amount so as to be uniform. Similarly, the small compartments 9 forming the other rows are also sequentially filled. In this way, all small compartments ( ₉₁₁ ,
After filling 9 ₁₂ to 9 ₄₆ ), all the filling ports 20c are sealed. The duvet 20 is completed through the above steps.

If, for example, futon cotton is used as the filling material 3 in addition to the feathers, the sewing of each of the small compartments 9 and the filling of the filling material 3 are performed at the same time, and finishing is performed in order from the rear small compartment. Alternatively, without forming a small section in advance, after filling the futon side bag with the futon cotton substantially uniformly, by stopping the front and back side fabric at several places by sewing at a predetermined part, or when the filling amount is small Prevents the movement of the filling by sewing the filling together with the filling from the outer surface of the side bag in a linear or curved shape in a straight line or in a curved shape.

[0010]

By the way, in the conventional futon having the above-mentioned form and manufacturing method, there is a drawback in that the workability of the main process is extremely poor and a large number of man-hours are required. That is, the finished size is 210 × 1
A large number of partition cloths 5 must be arranged in a grid pattern in the inside of the side bag 1 having a relatively large size of 50 (mm) to form small compartments. A large number of small compartments must be filled with an appropriate amount of feathers in order from the inner side by using hoses from the end of the side bag, and each compartment must be evenly filled. Also, if the size of the futon is different, it is suitable for each. This is a problem because the manufacturing work is complicated due to the fact that the material and the filling amount of the feather must be properly used.

In addition, such poor productivity is not limited to the surface cost problem, and it has been difficult to materialize an attempt to further improve the performance as a futon. For example, taking the current duvet as an example,
Although it is divided into about 6 to 24 compartments, with this number of divisions, the feathers (filler) may move during use and the usability may deteriorate. It is known that it is useful to subdivide into a larger number of compartments for the purpose of solving this problem, but since further increase in the number of manufacturing processes accompanying this cannot be tolerated, it has not been distributed. It is considered that it is preferable to subdivide only the neck portion where the filler is apt to move unevenly, but it is obvious that the work becomes more complicated as long as the conventional manufacturing method is used, and it is not applied at present. Alternatively, if you can easily and finely adjust the amount of filling in each compartment, you can increase the amount of filling at your feet when using, or set the amount of filling in the central part and the peripheral part differently to finely set the heat retention property. It is expected that it will be possible to improve the usability, but it is still not applied due to the poor workability of the filling work.

The futon and the method of manufacturing the same according to the present invention have been made in view of the above-mentioned circumstances. A novel structure and manufacturing method are proposed to significantly improve workability and productivity as compared with the conventional one. It was made for that purpose. In addition, as a result of this, the use performance depends on the fact that the compartments are subdivided further from the present in order to make the above-mentioned filling state uniform over a long period of time, or that different desired heat retention performance can be set for each part. It is also aimed to be able to supply futons with even better quality at an appropriate cost.

[0013]

In order to solve the above-mentioned problems, the futon according to the present invention has a bag-like front and back cloth side fabrics,
Inside the bag, which is made of breathable cloth and is formed into a substantially rectangular parallelepiped bag, the inside of the bag is divided into a plurality of rectangular compartments by dividing the inside with a partition cloth in the same width and in the same direction. It has a plurality of pouches of substantially the same width as the predetermined width that is filled with a filling such as feathers and then hermetically sealed, and the pouches are densely housed in a row in a row inside each of the rectangular compartments. Consists of Further, the method of manufacturing the futon of the present invention, a bag material made of a breathable cloth material is filled with a filler such as feathers and hermetically sealed to form a large number of pouch bodies, and these pouch bodies are formed into a bag shape with one end opening. Inside the side bag,
It is characterized in that it includes a step of tightly and densely housing and sealing the opening of the side bag.

[0014]

In the futon or the manufacturing method of the present invention, a plurality of pouch bodies and side bags are separately manufactured, and these are combined (assembled). Therefore, the small pouch body is easy to handle and has good workability. The filling work is easy to perform and the workability is improved. Furthermore, mechanization is possible. Secondly, the side bag is also provided with the internal partition wall only in one direction excluding the crossing portion, so that the workability is improved.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the drawings based on embodiments. FIG. 1 shows a plan view of a down duvet 10 which is an embodiment of the duvet of the present invention.
2 is a sectional view taken along line AA ′ and BB ′ of FIG. The futon 10 shown in the figure mainly has two types of portions, that is, cloth side fabrics (1a, 1b) on the front and back sides are formed in a bag shape, and the inside thereof is a partition cloth 5.
At the predetermined width W ', the side bag 1 is divided into a plurality of rectangular compartments 4 in the same direction, and inside the side bag 1, each rectangular compartment 4 is arranged in a row and in a row. Feathers inside the bag material 6 formed into a substantially rectangular parallelepiped bag made of breathable cloth material (nonwoven fabric or the like) as shown in FIG. The pouch body 2 has a width W ′ substantially the same as the above-described predetermined width W ′, which is formed by filling the filling material 3 and then sealing it.

Hereinafter, a method of manufacturing (assembling) the futon 10 of the embodiment will be described and each part will be described in detail. In the futon manufacturing method of the present invention, first, the side bag 1 and the pouch body 2 are separately manufactured as semi-finished products. First, the side bag 1 will be described. In this side bag 1, a partition cloth 5 having a predetermined width (in the figure, two partition cloths form an integral partition cloth) between the front and back side cloths 1a and 1b in one direction (for example, the futon longitudinal direction). It is attached to the front and back sides 1a and 1b and inserted inside,
In addition, the opening side 1d (sealed in a later step) by an appropriate means such as attaching the peripheral edge portions of the side grounds 1a and 1b by covering the edge cloth 1e.
To seal the bag into a bag shape as a whole, and to enclose a predetermined number of rectangular compartments 4 (4 ₁ , 4 ₂ ,
~ 4 ₄ ) are formed. The width W ′ of each rectangular compartment 4 is an integer fraction of the width dimension (4 in the figure) in order to divide the futon 10 into equal parts.
1) is set.

As described above, the partition cloth 5 may be attached to the inner surfaces of the front and back side fabrics 1a and 1b by using a thermocompression bonding machine or heat fusion. As described above, the side bag 1 is manufactured by a method approximately similar to that of the conventional one, but compared to the conventional one in which the partition cloth intersects, the partition cloth for one direction is completely unnecessary. The number of places is reduced and the fact that there is no partition cloth intersection also makes the work easier. In addition, the partition cloth itself has a simpler shape and is inexpensive and easy to handle.

Next, the pouch 2 will be described. As shown in FIG. 3 (a), the pouch body 2 has a substantially rectangular parallelepiped-shaped bag material 6 formed of a material having good air permeability such as a nonwoven fabric,
Next, it is manufactured by filling the inside with a filling material 3 such as feathers and then sealing and sealing, and its width W is set to be slightly larger than the width dimension of the rectangular compartment 4. Further, the length L is set to be slightly larger than an integer fraction of the length L'of the futon. Therefore,
By arranging the pouch bodies 2 having the same size in a predetermined row and a predetermined row, the size of the futon becomes substantially large. As described above, since the pouch body 2 is small and has the same size in the embodiment, the work of forming the pouch material 6 by adhering, sewing or the like and the work of filling the filling material 3 are extremely easy. Moreover, since it is only necessary to mass-produce the pouch body 2 of the same size, that is, the standard product, it is possible to mechanize the forming work and the filling work and further reduce the manufacturing cost.

The main parts are aligned in the steps described above, and then these are assembled (assembled). That is, a predetermined number of the pouch bodies 2 are inserted and housed in each of the rectangular compartments 4 of the side bag 1 from the opening side 1d in a row and a row. Figure 5 is a view for describing a manner of inserting the pouch body 2 in a rectangular parallelepiped compartment 4 _1. Although the pouch body 2 has a slightly larger size as described above, since it has sufficient elasticity and is freely deformable, it can be easily inserted and housed, and after being housed, it appropriately expands. That is, the respective pouch bodies 2 are tightly accommodated and brought into close contact with each other. After the accommodation of the pouch bodies 2 in all the rectangular compartments 4 is completed, the opening side 1d of the side bag 1 is sealed by an appropriate method to complete the futon 10 of the embodiment.

For convenience of transportation and the above-mentioned insertion and storage work, one rectangular compartment 4 is provided as shown in FIG. 3 (b).
A predetermined number of pouch bodies 2 to be housed together are connected in advance in one row and one row by sewing or the like, and pouch connection body 7 (2)
Alternatively, the pouch connection bodies 7 may be inserted into the respective rectangular compartments one by one.

By applying the above-described technique, several kinds of pouch bodies are manufactured by sacrificing the standardization of the pouch body and varying the filling amount, and the workability is slightly reduced during the assembly with the side bag. If you accept the above, you can make detailed consideration such as distributing soft and hard parts in the longitudinal direction as intended in the longitudinal direction and distributing different heat retention properties in the longitudinal direction as intended. It is possible to provide a futon having a good feeling of use. In addition, it is possible to adjust the hardness and heat retention along the width direction of the futon.

Further, in the embodiment, since the side wall portions of the pouch body are distributed in a line in the width direction in the futon, the portions having high rigidity are distributed on a straight line, and there may be anxious users. Be done. For this purpose, for example, the futon 1 shown in FIG.
Two types of pouches with different lengths L such as 0 '(2,
It is also possible to improve the uniformity of the futon by avoiding the side wall positions of the adjacent rectangular compartments 4 being displaced and forming a straight line by preparing 2 ′) and appropriately arranging them.

In the above embodiment, the pouch bodies 2 are individually formed and housed in the respective rectangular compartments 4 and continuously arranged. On the contrary, first, the length substantially corresponding to the length of the futon is set. The bag-like object 8 may be formed in advance, and after the feathers 3 are filled therein, the pouch body 2 may be formed by appropriately dividing and dividing in the longitudinal direction. Another embodiment of such a pouch is a plan view of FIG. 4 (a) and (b).
Is shown in the side sectional view of FIG. The pouch connection body 8 shown in the figure is the bag-like object 8 first.
A is formed into a bag shape leaving an opening at one end in the longitudinal direction, and an appropriate amount of feathers (filling material) 3 is filled into the inside of the bag 8A substantially uniformly from the opening, and then FIG. As shown in both figures, the front and back are sewn in the width direction at a predetermined position (sewn portion 8b) in the longitudinal direction, whereby a desired number of pouch bodies 2 are formed. In the same manner as described above, the pouch connection body 8 thus formed is
By inserting and housing in each rectangular compartment 4 of the side bag 1,
The pouch bodies 2 can be arranged in a row and a row. In this case, it is advisable to form the length of the above-mentioned pouch connection body 8 to be slightly longer than the length of the futon (for example, 210 mm).
(About 240 mm with respect to the length of the futon), and after being accommodated in the side bag 1, the respective pouch bodies 2 expand and adhere to each other in the side bag 1,
The constriction generated in the sewn portion 8b does not affect the outer surface, and thus the outer surface of the futon is flat, which is preferable.

According to the above-mentioned method, it is possible to extremely easily obtain the compartment, that is, the pouch body 2, which is remarkably subdivided as compared with the conventional one, and it is possible to effectively suppress the movement of the filling material.
Further, in this method, as shown in FIG. 4, the length of the series of pouch bodies 2 can be changed very easily. Therefore, it is possible to prevent the unevenness by subdividing the portion where the filling 3 is more likely to shift than others. Further, by making the lengths different, it is possible to distribute the soft portion and the hard portion in the longitudinal direction of the futon as intended, and it is also possible to provide a futon having a good usability that has never been seen before. It is possible to adjust the hardness of the futon along the width direction if desired (the packing density of the connected sachets is different for each rectangular compartment), but the workability is slightly improved due to the standardization of the parts used. Getting worse.

As is clear from the above description, the futon of the present invention is formed of a breathable cloth material in the shape of a bag, and is filled with a filling material such as feathers and then sealed. The body and the inside are divided into a plurality of rectangular compartments having the same width as the width of the pouch body and formed in the same direction, and the pouch bodies are housed in one row and one row inside each rectangular compartment. It is composed of a side bag made of cloth side cloth, and therefore exhibits many of the features described above.

Such a futon is made by the method for producing a futon of the present invention, that is, a bag material made of a breathable cloth material is filled with a filler such as feathers and sealed to form a large number of small bag bodies, and these small bag bodies are formed. Can be manufactured by accommodating the above in one step and tightly inside the bag-like side bag having one end opened, and sealing the opening of the side bag. Note that the present invention can be applied to a futon that uses, for example, futon cotton as the filler 6 in addition to the feathers and the manufacturing thereof.

[0027]

As described in detail above, the futon of the present invention is
Side cloth made of cloth on the front and back is formed into a bag, and the inside is divided into a plurality of rectangular compartments by dividing it with a partition cloth in the same width in the same direction, and a side bag with a substantially rectangular parallelepiped shape. The bag material made of breathable cloth has a plurality of pouch bodies of substantially the same width as the predetermined width formed by filling a filling material such as feathers inside and then sealing the pouch body, each of the rectangular parallelepipeds. It is configured to be housed in a row in a row and densely inside the compartment, and since a plurality of pouch bodies and side bags are separately manufactured and combined together, a small pouch body has good workability during formation or filling. Also, the side bag is easy to form, workability in combination is good, and overall workability and productivity are significantly improved compared to conventional products.

In the method of manufacturing a futon according to the present invention, a bag material made of a breathable cloth material is filled with a filling material such as feathers and hermetically sealed to form a large number of pouch bodies. Since it includes a step of tightly and tightly accommodating the inside of the bag-shaped side bag and sealing the opening of the side bag, the futon can be manufactured with good workability and productivity. As a result, it is possible to realize a futon, which has a performance that could not be provided in the past.

[Brief description of drawings]

FIG. 1 is a plan view showing an embodiment of a futon according to the present invention.

FIG. 2 is a side sectional view in which the futon of the embodiment of FIG. 1 has different directions.

FIG. 3 is a perspective view showing an embodiment of the pouch according to the present invention, and a side cross-sectional view of a pouch connection in which the pouch is connected.

4A and 4B are a plan view and a side sectional view showing an embodiment of a pouch connection body according to the present invention.

FIG. 5 is a plan view showing a part of the futon to explain the present invention.

FIG. 6 is a plan view showing another embodiment of the futon according to the present invention.

FIG. 7 is an enlarged side view showing an example of a conventional futon.

FIG. 8 is a plan view of the conventional futon of FIG. 7.

[Explanation of symbols]

1 ... side bags, 2 ... pouch body, 3 ... packing, 4 (4 _1, 4 _2, -, 4 ₄₎ ... rectangular compartment, 5 ... bulkhead cloth, 6 ... bag material, 10, 10 '... duvet.

Claims (2)

[Claims] 1. A plurality of rectangular compartments (4) are formed by dividing the inside and outside of the cloth side cloth into a bag shape and dividing the inside by a partition cloth (5) with a predetermined width in the same direction. Side bag (1) and bag material (6) made of breathable cloth that is formed into a substantially rectangular parallelepiped bag
Has a plurality of pouches (2) having substantially the same width as the predetermined width, which is formed by filling a filling material (3) such as feathers inside and then sealing the pouch body (2) in each of the rectangular parallelepipeds. A futon that is densely housed in a row and in a row inside the compartment (4). 2. A bag material made of a breathable cloth material is filled with a filling material such as feathers and hermetically sealed to form a large number of small bag bodies, and these small bag bodies are provided in a bag-like side bag having one end opening and further And a method of manufacturing a futon, which includes a step of tightly accommodating and tightly sealing the opening of the side bag.