JPH05176831A - Cushion material and its production - Google Patents

Abstract

PURPOSE:To provide a cushion material of unified structure and which is excellent in the appearance, light in the weight and independent in coil springs and also has not much lateral swing its production method. CONSTITUTION:A packed material 1 is made so as to envelop continuous pocket coils composed of many pocket coil units containing a single coil spring in each bag by means of a first integrated fibrous material having a sheet and bag shape composed of combined fibers including heat-melting fibers. One or more packed materials are arranged to have an appropriate form to make an arranged and packed material 3. After that, second integrated fibrous materials 4, 5 having a sheet form made of these combined fibers are arranged in accordance with necessities and heated to unify them. A combined fiber-made bag type pocket coil in which a lot of pocket coil units containing a coil spring in each bag composed of combined fibers are continuously arranged is made in stead of the packed material 1. The bag type pocket coils may be arranged to form a disposing pocket coil body.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material and a method of manufacturing the same, and more specifically, it has a coil spring having independence and a partial hardness can be adjusted by combining the coil springs in a block unit. Further, the present invention relates to a cushion material having a uniform hardness, a light weight, and a small amount of sound due to an integrated structure of the coil spring and the skin, and a manufacturing method thereof. INDUSTRIAL APPLICABILITY The present invention is used for bed mattresses, chairs, automobile sofas, and other mattresses.

[0002]

2. Description of the Related Art In a conventional mattress, the upper and lower surfaces of a plurality of coil springs arranged in rows and columns are connected by helical lines to form a plurality of spring units. An outer frame line is provided in the peripheral portion of the spring, and the outer frame line and the upper surface of each spring are fixed by a joint member. An elastic body is arranged on the spring unit. In addition, a pocket coil spring unit and the like are known as those using an independent coil spring (actually disclosed in Japanese Utility Model Laid-Open No. 2-1272).
68).

[0003]

However, in the above-mentioned conventional mattress, a step of winding a helical wire is required, and the helical wire may come out by being used. Further, an outer frame line is required, which makes it heavy, and since each joining member is attached individually, the process is complicated. Further, when arranging the coil springs, it is practically difficult to change the diameter or the number of the springs to form a functional structure, and the spring unit and the elastic bodies arranged above and below the spring unit are not integrated. Therefore, there has been a problem that buttoning or the like is required in the subsequent process. Further, even when the above-mentioned known pocket coil spring unit is used, the outer frame line is similarly required to fix and hold the whole, which is heavy and has a problem in appearance, and the like. Further, even if the outer frame line is not required, it is necessary to bond the adjacent pocket coils, which complicates the manufacturing process. Furthermore, there is a problem that lateral shake easily occurs.

The present invention overcomes the above-mentioned drawbacks and has an excellent appearance, a simple structure, less lateral vibration, no squeaking noise of the spring, light weight, and easy partial hardness adjustment. An object of the present invention is to provide an integrally structured cushioning material having independent coil springs and a manufacturing method thereof.

[0005]

The method for manufacturing a cushioning material according to the first aspect of the present invention is a sheet-shaped, tubular or bag-shaped first structure made of mixed fibers composed of heat-welding fibers and non-heat-welding fibers. Using the fiber assembly, a pocket coil, in which a large number of pocket coil units each containing one coil spring is housed in each bag body, is wrapped to produce a pocket coil package of the first fiber assembly. After that, one or more of the packages are arranged in an appropriate shape to produce an array package, and then these are heated and integrally molded.

In the manufacturing method of the second aspect of the present invention, a large number of pocket coil units in which one coil spring is housed in each bag of continuous mixed fibers composed of heat-welding fibers and non-heat-welding fibers are continuous. The pocket coil is adhered to the surface of the bag body of the pocket coil with an adhesive to produce a pocket coil coating of the above-described mixed fibers, and then one or more of the coatings are arranged in an appropriate shape to form an array coating. Is manufactured, and then these are heated to be integrally molded. Book third
The manufacturing method of the invention arranges one or more pocket coils, in which a large number of pocket coil units each containing one coil spring are continuous in a bag, in an appropriate shape, and thereafter,
A mixed fiber composed of a weldable fiber and a non-heat-weldable fiber is inserted between the bag bodies of the pocket coil to produce an array covering body, which is then heated and integrally molded. And

According to the manufacturing method of the fourth aspect of the present invention, a large number of pocket coil units in which one coil spring is housed in each bag formed of a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber are continuous. The mixed fiber bag-shaped pocket coil thus prepared is manufactured, and then one or more of the mixed fiber bag-shaped pocket coils are arranged in an appropriate shape to manufacture a mixed fiber bag-shaped arrayed pocket coil body. It is characterized in that these are heated and integrally molded. A manufacturing method according to the fifth aspect of the present invention is a sheet-like structure composed of a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber on the upper surface and the lower surface of the array package, array cover or array pocket coil body. Alternatively, a plate-shaped second fiber assembly is arranged.

The manufacturing method of the sixth invention is a hardness adjusting material having a lattice or a mesh on at least one of the upper surface and the lower surface of the array package, the array cover or the array pocket coil body. And then, on at least the upper surface and the lower surface of these arrays, a second mixture of mixed fibers of heat-weldable fibers and non-heat-weldable fibers.
The fiber assembly is arranged. The manufacturing method according to the seventh aspect of the present invention comprises a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber between the array packaging body, the array coating body or the array pocket coil body, and the hardness adjusting material. The sheet-shaped or plate-shaped second fibrous structure is disposed.

According to the eighth aspect of the present invention, there is provided (A) a heat-welding fiber or a heat-welding fiber on at least one of the upper surface and the lower surface of the array package, array cover or array pocket coil body. Formulated with fusible resin powder,
A sheet in which (B) heat-fusible fiber or heat-fusible resin powder is adhered or arranged on the surface, or (C) a sheet-like fiber assembly containing the heat-fusible fiber is sewn or bonded to the surface and joined. -Shaped or plate-shaped palm fiber assembly is arranged, and then a second fiber assembly composed of mixed fibers composed of heat-weldable fibers and non-heat-weldable fibers on at least the upper surface and the lower surface of these array bodies Are arranged, and these are heated to be integrally molded. Further, as shown in FIG. 6, a mixture of the heat-welding fiber and the non-heat-welding fiber is provided between the array packaging body, the array coating body or the array pocket coil body 3 and the palm fiber assembly 8. Sheet-like or plate-like second fiber assembly 6 made of fibers
Can be placed.

The cushioning material of the fourteenth aspect of the present invention is an array pocket coil body in which a plurality of pocket coil rows in which a plurality of pocket coils each containing one coil spring are continuous are arranged, and the cushion material of each of the bag bodies is provided. A fiber-welded coating body integrally configured to cover the bag body, comprising a heat-weldable fiber and a non-heat-weldable fiber, and having a joint formed by heat-welding the heat-weldable fiber, It is characterized by being integrally provided. In the cushion material according to the fifteenth aspect of the present invention, a hardness adjusting material having a lattice or a mesh is arranged inside the fiber-welded molded body portion located on at least one of the upper surface and the lower surface of the coil spring. The adjusting material, the coil spring, and the fiber-welded molded body are integrally configured.

The cushioning material of the sixteenth aspect of the present invention comprises: (A) a heat-welding fiber or a heat-welding fiber inside a fiber-welded molded body portion located on at least one of the upper surface and the lower surface of the coil spring. Blended with resin powder,
A sheet in which (B) heat-fusible fiber or heat-fusible resin powder is adhered or arranged on the surface, or (C) a sheet-like fiber assembly containing the heat-fusible fiber is sewn or bonded to the surface and joined. A palm fiber welded body having a joint formed by heat-welding the heat-weldable fibers in a sheet-shaped or plate-shaped palm fiber aggregate, the palm fiber aggregate, the coil spring, and the fiber-welded molding The body is characterized in that it is constructed in one piece.

In the above invention, the shape and size of the coil spring, the thickness of the wire rod, the number of uses, the number of turns of one spring, etc. are variously selected according to the purpose and application. In addition, the above-mentioned "mixed fiber consisting of heat-welding fiber and non-heat-welding fiber" includes other functional fibers (for example, fibers having antibacterial action or deodorant action, super absorbent fiber, etc.). It is meant to include things. The above-mentioned heat-fusible fiber mainly has heat-bonding (welding, fusing) action, and has a low melting point polyester fiber, polyethylene fiber, polypropylene fiber, polyvinyl chloride fiber, nylon fiber and ethylene vinyl acetate copolymer. One kind or two or more kinds of fibers and the like can be used. When these are heated to a high temperature, they disappear to become balls and have a function of bonding fibers. In addition, when only the surface is melted without being heated to a high temperature up to this point, the fiber itself does not disappear. Further, an adhesive core-sheath type comprising a core made of a high melting point polyester fiber and a coating part made of a thermoplastic resin which covers the core and has a melting point lower than the melting point of the high melting point polyester fiber by 30 ° C. or more. It can also be a fiber. In the case of this core-sheath fiber, since it does not disappear by itself, there is little decrease in volume, and because the core fiber is a high melting point polyester, it has excellent thermal properties (heat resistance, etc.) and mechanical properties.

As the non-heat-welding fiber, one having a melting point higher than that of the heat-welding fiber may be used, and a fiber having a high melting point of 150 to 280 ° C. is usually used. As this fiber, polyethylene terephthalate,
Polyester fibers made of polyhexamethylene terephthalate, polytetramethylene terephthalate, etc., other synthetic fibers, natural fibers and the like can be used.

The mixing ratio of the above-mentioned heat-weldable fiber and non-heat-weldable fiber is usually appropriately selected within the range of 10:90 to 80:20 by weight. This makes it possible to obtain a cushion material having desired performance. That is, if the blending ratio of the heat-fusible fiber is increased, a soft material can be obtained throughout the cushion material, while if it is decreased, a soft material can be obtained throughout the cushion material. If the content of the heat-weldable fiber is less than 10%, the heat-bonding between the adhesive fibers is insufficient and the cushioning property tends to be deteriorated. On the other hand, if it exceeds 80%, the bonding point becomes excessive and the produced cushioning material is Because it is too hard. Therefore, it is possible to fill each of the coil springs with the mixed fibers in which the mixing ratio of the heat-welding fibers and the non-heat-welding fibers is changed to change the hardness depending on the site. Also, heat-weldable fiber,
The shape of the non-heat-welding fiber (whether curled or not), thickness, length, etc. can be variously selected according to the purpose and application.

The above heating is for melting or sufficiently softening the fibers so that the adhesive fibers are heat-bonded to each other. As the heating means, hot water, steam, wet heat means such as high-pressure steam, hot air, dry heat means such as heating furnace, far-infrared ray heating, high-frequency heating and the like can be used. It can also be used together. Further, not only the atmosphere but also the above heating air or heating steam may be introduced under vacuum to perform heating. Also,
(A) It is also possible to press and arrange a predetermined array in a predetermined mold, particularly a mold (upper mold, lower mold, etc.), and to heat the mold. But you can
(B) It is possible to heat only the upper part or only the upper part and the lower part in a state of being pressed by a predetermined plate-like body or a belt without the need for molding, and (C) there is no such thing. It is also possible to heat the array as it is so that it is enclosed so as not to be separated. In order to obtain a molded product having a desired shape, it is preferable to heat in a pressed state. Further, the packing method is not particularly limited, and may be arranged in a matrix, alternately arranged in a dense arrangement, randomly arranged, or another arrangement. It may be a method.

[0016]

EXAMPLES The present invention will be specifically described below with reference to examples. Example 1 In this example, as shown in FIG. 1, FIG. 3 and FIG. 8, cushion cushions for mattresses for beds are manufactured.
First, as shown in FIG. 1, a well-known pocket coil 11 is prepared in which a large number of pocket coil units each containing one coil spring 11b in each bag 11a are continuous.
Then, the pocket coil 11 is packaged using the sheet-shaped first fiber assembly and sewn with a thread so as to form a bag (13 is a seam), and the entire pocket coil 11 is formed into a bag-shaped first coil. The wrapping body is manufactured by inserting it into the fiber assembly 12 by tapping. In addition, a seam may be vertically provided for each pocket coil unit.

As this coil spring, a drum shape (or drum shape), 3 to 5 windings, and a diameter of both sides of about 65 m
m, the diameter of the central part is about 40 mm, the wire thickness is about 2 mm, and the total height is 140 mm.
As the material of the bag body for wrapping 1b, a commonly used one was used. A drum-shaped spring is preferable because the space between the first fibrous structure and the spring is smaller. As the fiber assembly (thickness; about 4 to 8 mm) 2, a lightly punched one made of a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber was used. The first fibrous structure may not be punched, and the degree of punching is not particularly limited.

The heat-weldable fiber has a fineness of 2 to 15
A denier fiber having a fiber length of about 51 mm was used. Polyethylene having a melting point of 110 to 130 ° C. was used as the sheath portion of this fiber, and polyester fiber having a high melting point (about 250 to 280 ° C.) was used as the core portion. The non-heat-weldable fiber has a melting point of about 250 ° C. (13 denier,
A fiber length of 51 mm) was used. The weight ratio (non-heat-welding fiber / heat-welding fiber) is [80/20] to [30/7].
0] was appropriately blended.

This package 1 is arranged in a matrix [9 rows × 26 pieces (1
Array)] to produce the array package 3. And
Sheet-shaped second fiber aggregates (thickness: about 40 to 60 mm) 4 and 5 composed of the same mixed fibers were arranged on the upper surface, the lower surface and the side circumference of the array package 3, respectively. These are pressed in the mold at 160-200 ° C for about 30-
After heating for 60 minutes, the fusible fibers were welded together and integrally molded to manufacture the cushioning material shown in FIG.

The present cushioning material completely covers the coil spring with the fiber-welded aggregate, and they are integrally formed. Since the frame spring and the retaining clip are not present, the appearance is good and the weight is reduced. Moreover, the manufacturing thereof is extremely simple, there is no lateral vibration, there is no squeaking noise generated from the coil, and the cushion material having a desired shape corresponding to the cavity shape of the mold can be easily manufactured. Further, since the coil springs are not coupled to each other and are independent, they function as independent springs.

Further, since the fusible fiber used has a high melting point polyester fiber as a core, the fusible fiber does not disappear even after heating, and the volume of the molded product shrinks little, so that there is no particular compression step. However, it is possible to manufacture a molded product having a desired shape and to maintain sufficient elasticity. Furthermore, since polyester fibers are used for both the fusible fibers and the non-fusible fibers, they have excellent heat resistance, durability, weather resistance, strength, etc., and therefore can be safely used in automobiles.

Example 2 In this example, as shown in FIGS. 4 and 9, the hardness adjusting material 7 is arranged on the array package 3, and the integrally molded product shown in FIG. To manufacture the cushion material. The hardness adjusting material has a mesh of 20 to 40 m.
m, the width of the constituent line portion is 3 to 5 mm, and the thickness is 2 to
It is a 4 mm resin integrated lattice (insulator). The material of the hardness adjusting material, the size of the mesh, the line width, etc. can be variously changed and used depending on the purpose and application. This cushion material has the effects of the first embodiment, the hardness of the cushion is adjusted appropriately, and is suitable as a bed cushion. Further, even if such a hardness adjusting material is used, since it has a mesh, it is completely fixed between the welded fibers and is excellent in its integrity.

Example 3 In this example, the palm fiber assembly 8 is used as an intermediate placement material. For example, as shown in FIG. 5, the palm fiber assembly 8 is arranged directly on the array packaging body 3, and the palm fiber assembly 8 is arranged as shown in FIG.
It is possible to manufacture a cushion material which is an integrally molded product shown in FIG. Further, as shown in FIG. 6, the third fiber assembly 6 is arranged on the array packaging body 3, and the palm fiber assembly 8 is arranged on the third fiber assembly 6 to form a cushion material (FIG. 11). Can also be manufactured.

In this case, the palm fiber assembly may be one that is heat-welded with the heat-welded fibers arranged above and below the fiber to be integrated (bonded). For example, when (A) this palm fiber assembly is manufactured, a predetermined palm fiber and a predetermined amount of heat-welding fiber or heat-welding resin powder are mixed, and (B) conventional palm fiber assembly Those which are heat-welded fibers or heat-weldable resin powder adhered and fixed to both sides of the same with an adhesive, or are sprinkled with the fibers or the like on both sides thereof and filled and arranged between the palm fibers to some extent, further , (C) a sheet-shaped fiber assembly containing the heat-fusible fiber may be sewn or adhered to the surface to be joined. Here, the heat-fusible resin powder may be made of a material forming the heat-welding fiber, or may be a mass of the fiber. Since the palm fiber aggregate is integrally provided in the product of this example, it provides appropriate hardness and is also excellent in breathability and water absorption.

The present invention is not limited to the specific examples described above, and various modifications may be made within the scope of the present invention according to the purpose and application. That is,
For example, as shown in FIG. 1, the packaging body 1 of the pocket coil 11 made of the first fiber assembly 12 is arranged in an appropriate shape,
The cushion material shown in FIG. 7 can be manufactured by heating and molding as it is. That is, it is possible to manufacture a product in which the second fibrous structure and the hardness adjusting material are not arranged. Further, instead of the wrapping body in the above embodiment, a pocket coil covering body 2 made of mixed fibers as shown in FIG. 2 can be used. This is the predetermined pocket coil 21
It is manufactured by adhering a predetermined mixed fiber with an adhesive (not shown) to the surface of the bag body 21a constituting the.
As the adhesive, a rubber adhesive or the like is used, and it is sufficient that the adhesive can be adhered by spraying or the like in places where it can be temporarily fixed. Furthermore, arrange the predetermined pocket coil in an appropriate shape,
After that, a predetermined mixed fiber can be inserted between the bags of the pocket coil to manufacture an array covering body.

The shape and size of the coil spring, the thickness of the wire used, the size of the coil sung row, the presence or absence of lamination, the kind of mixed fiber, the mixing ratio, etc. can be variously selected depending on the purpose and application. The first fibrous structure and the second fibrous structure may be of the same kind or of different kinds, and the number of layers of this fibrous structure is not limited to one, and may be many if desired to be thick. The thickness may be increased. The means for wrapping the pocket coil with the fiber assembly is not particularly limited, and for example, a bag-shaped body with one end open or a cylindrical body with both ends open is made first, and the pocket coil is inserted into this bag. However, the opening may be sewn and closed, or the opening may be bent and not closed.

As the used fibers, used fibers can be used. In this case, the resources can be reused excellently and the cost can be reduced. Further, the second fibrous assembly may be provided only on the upper and lower surfaces of the arrayed package, and the side circumference thereof may not be covered. Even when covering the side circumference, it is not necessary to completely cover the side circumference as in the above embodiment. Alternatively, it may be configured to cover a part (for example, the upper side and the lower side) thereof.

Furthermore, the mixed fibers in which the mixing ratio of the heat-welded fibers and the non-heat-welded fibers are changed can be filled by changing the position. For example, the central portion where the person lies down is a hard cushion portion, and the surrounding portion is surrounded. One can also use a slightly soft cushion part. Further, the cushion material is not limited to the bed cushion material, and may be an automobile cushion material or the like as shown in FIG. 14, and can be freely designed by using a mold according to the target shape. Also in FIG. 14, the a portion can be made hard and the b portion can be made soft. In this case, in the portion a, the mixing ratio (weight ratio) of the weldable fiber and the non-weldable fiber used in the above example should be about 70/30, while in the portion b, about 20/80. You can

Further, both the palm fiber assembly and the hardness adjusting material can be used in combination, and the array packaging body or the like can be arranged not only on one surface but also on both surfaces. It is also possible to alternately laminate these with other fiber aggregates. The above invention is used to include such a laminated body. In addition, these hardness adjusting materials or palm fiber aggregates can be arranged in a desired portion to be hardened. Even in this case, these hardness adjusting materials and the like are integrally fixed and held in the molded body. Further, as shown in FIG. 15, an assembled body in which cushioning materials having different hardnesses are manufactured and arranged according to the purpose, for example, the centrally arranged one (A) is more than the other one (B). It can also be a hardened configuration.

[0030]

As described above, according to the cushioning material and the manufacturing method thereof of the present invention, the appearance is excellent, the structure is simple,
It is possible to provide an integrally structured cushioning material that has less lateral vibration, eliminates the squeaking noise of the spring, has excellent independent cushioning performance, and facilitates partial adjustment of hardness. Further, since it has an independent spring, when incinerated, only a plurality of springs remain independently, and a large frame body fixed by a frame line or the like does not remain, which is very convenient for the disposal of the cushion material. Furthermore, in order to obtain a final product such as a bed, it is not necessary to provide a skin, and the cushion material of the present invention is simply wrapped or wrapped with a sheet or the like,
It can be the final product.

[Brief description of drawings]

FIG. 1 is a partial perspective view of a package according to a first embodiment.

FIG. 2 is a partial perspective view of a covering body obtained by adhering mixed fibers to the surface of a bag body of a pocket coil with an adhesive.

FIG. 3 is a schematic explanatory diagram illustrating a method for manufacturing a cushion material according to the first embodiment.

FIG. 4 is a schematic explanatory view showing a method for manufacturing a cushioning material in Example 2.

FIG. 5 is a schematic explanatory view showing a method of manufacturing a cushioning material in Example 3.

FIG. 6 is a schematic explanatory view of a method for manufacturing a cushioning material showing another aspect of the third embodiment.

FIG. 7 is a partial vertical cross-sectional view of a cushion material manufactured by heating a predetermined array package without using the first fiber assembly.

FIG. 8 is a partial explanatory cross-sectional view of the cushion material manufactured in Example 1.

FIG. 9 is a partial explanatory cross-sectional view of a cushion material manufactured in Example 2.

FIG. 10 is a partial explanatory cross-sectional view of a cushion material manufactured in Example 3.

FIG. 11 is a partial explanatory cross-sectional view of a cushioning material manufactured in Example 3 using a predetermined palm fiber assembly.

FIG. 12 is a perspective view of a cushion material for an automobile.

FIG. 13 is an overall perspective view of an assembled body in which five cushion materials are combined.

[Explanation of symbols]

1; wrapping body, 11; pocket coil, 11a; bag body, 1
1b; coil spring, 12; first fiber aggregate, 2;
Cover body, 21; pocket coil, 21a ;; bag body, 2
3; mixed fiber, 4; second fiber assembly, 5; second fiber assembly, 6; third fiber assembly, 7; hardness adjusting material (insulator), 8: palm fiber assembly.

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[Procedure amendment]

[Submission date] November 30, 1992

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] 0025

[Correction method] Change

[Correction content]

The present invention is not limited to the specific examples described above, and various modifications may be made within the scope of the present invention according to the purpose and application. That is,
For example, as shown in FIG. 1, the packaging body 1 of the pocket coil 11 made of the first fiber assembly 12 is arranged in an appropriate shape,
The cushion material shown in FIG. 7 can be manufactured by heating and molding as it is. That is, it is possible to manufacture a product in which the second fibrous structure and the hardness adjusting material are not arranged. Change
First, as shown in FIG. 12, a predetermined mixed fiber is formed.
One coil spring 11b in each bag 12 formed
Mixing with a large number of pocket coil units stored in series
Manufactures a bag-type pocket coil made of fiber. And this
Predetermine the upper and lower sides of the array body arranged in an appropriate shape and the side periphery.
A second fibrous assembly consisting of mixed fibers is placed and then one
Physically heat and mold to produce the cushion material shown in FIG.
It can also be built. Further, instead of the wrapping body in the above embodiment, a pocket coil covering body 2 made of mixed fibers as shown in FIG. 2 can be used. This is to bond a predetermined mixed fiber to the surface of the bag body 21a forming the predetermined pocket coil 21 with an adhesive (not shown),
It is manufactured. A rubber-based adhesive or the like is used as this adhesive, and it is sufficient that it can be adhered by spraying or the like in places where it can be temporarily fixed. Furthermore, it is also possible to fabricate an array covering body by arranging predetermined pocket coils in an appropriate shape and then inserting a predetermined mixed fiber between the bag bodies of the pocket coils.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Correction target item name] Figure 12

[Correction method] Change

[Correction content]

FIG. 12 is an explanatory diagram of a mixed fiber bag type pocket coil in which a large number of pocket coil units are continuous.

[Procedure 3]

[Document name to be amended] Statement

[Name of item to be corrected] Fig. 13

[Correction method] Change

[Correction content]

13 is a partial vertical cross-sectional view of a cushion material manufactured using the mixed fiber bag-type pocket coil shown in FIG.

[Procedure amendment 4]

[Document name to be amended] Statement

[Name of item to be corrected] Fig. 14

[Correction method] Added

[Correction content]

FIG. 14 is a perspective view of a cushion material for an automobile.

[Procedure Amendment 5]

[Document name to be amended] Statement

[Correction target item name] Fig. 15

[Correction method] Added

[Correction content]

FIG. 15 is an overall perspective view of an assembly in which five cushion materials are combined.

Claims (18)

[Claims] 1. A coil spring in each bag using a sheet-shaped, tubular-shaped, or bag-shaped first fiber aggregate composed of mixed fibers composed of heat-weldable fibers and non-heat-weldable fibers. A package of pocket coils made of the first fiber assembly is produced by wrapping a pocket coil in which a large number of pocket coil units each containing the package are stored, and then one or more of the package is arranged in an appropriate shape. Then, the array packaging body is manufactured, and then these are heated to be integrally molded. 2. A bag body of a pocket coil, wherein a plurality of pocket coil units, each containing a coil spring containing a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber, are continuous in each bag body. By adhering to the surface with an adhesive to produce a pocket coil coating of the above-mentioned mixed fibers, one or more of the coatings are arranged in an appropriate shape to produce an array coating, and then these are coated. A method for manufacturing a cushioning material, characterized by being heated and integrally molded. 3. One or more pocket coils in which a large number of pocket coil units each containing one coil spring are connected in a bag body, and one or more pocket coils are arranged in an appropriate shape, and thereafter, between the bag bodies of the pocket coils. 1. A method for producing a cushioning material, comprising the steps of: inserting a mixed fiber composed of a weldable fiber and a non-heat-weldable fiber into an array to produce an array covering body, and then heating and integrally molding them. 4. A mixed-fiber bag type in which a large number of pocket coil units in which one coil spring is housed in each bag formed of mixed fibers composed of heat-weldable fibers and non-heat-weldable fibers are continuous. A pocket coil is manufactured, and then one or more of the mixed fiber bag type pocket coils are arranged in an appropriate shape to manufacture a mixed fiber bag type arrayed pocket coil body, which are then heated to be integrated. A method for manufacturing a cushion material, which is characterized in that 5. A sheet-like or plate-like structure made of a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber on the upper surface and the lower surface of the array package, the array cover or the array pocket coil body. The method for manufacturing a cushioning material according to any one of claims 1 to 4, wherein the second fibrous structure is arranged, and these are heated to be integrally molded. 6. A hardness adjusting material having a lattice or a mesh is disposed on at least one of the upper surface and the lower surface of the array package, the array cover or the array pocket coil body, and then these are arranged. A second fiber assembly composed of a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber is disposed on at least the upper surface and the lower surface of the array, and these are heated to be integrally molded. The method for manufacturing the cushion material according to any one of 1 to 4. 7. A sheet shape composed of a mixed fiber composed of a heat-weldable fiber and a non-heat-weldable fiber, between the arrayed package, the arrayed cover or the arrayed pocket coil body and the hardness adjusting material. Alternatively, the method for manufacturing the cushioning material according to claim 6, wherein a plate-shaped second fiber assembly is arranged. 8. The (A) heat-welding fiber or heat-welding resin powder is blended on at least one of the upper surface and the lower surface of the array package, array cover or array pocket coil body. , (B) the heat-fusible fiber or the heat-fusible resin powder is adhered or arranged on the surface, or (C) the sheet-like fiber assembly containing the heat-fusible fiber is sewn or bonded to the surface to be joined. A sheet-shaped or plate-shaped palm fiber assembly is arranged, and then a second fiber assembly composed of a mixed fiber composed of a heat-weldable fiber and a non-heat-weldable fiber is provided on at least the upper surface and the lower surface of these arrays. The method for manufacturing a cushioning material according to any one of claims 1 to 4, wherein the body is arranged, and these are heated to be integrally molded. 9. A sheet made of a mixed fiber composed of a heat-weldable fiber and a non-heat-weldable fiber between the arrayed package, the arrayed cover or the arrayed pocket coil body and the palm fiber assembly. The method for manufacturing a cushioning material according to claim 8, wherein the second fibrous aggregate having a plate-like or plate-like configuration is arranged. 10. A core made of a low melting point polyester fiber, a polyethylene fiber, a polypropylene fiber, a polyvinyl chloride fiber, a nylon fiber, an ethylene vinyl acetate copolymer fiber, and a high melting point type polyester fiber, and the core. From the melting point of the high melting point polyester fiber
One or two of the adhesive core-sheath type fibers and the like, which are composed of a covering portion made of a thermoplastic resin having a low melting point of 0 ° C. or more
The method for producing a cushion material according to claim 1, wherein the cushion material is one or more kinds. 11. The heat-fusible fiber comprises a core made of a high melting point polyester fiber and a coating part made of a thermoplastic resin which covers the core and has a melting point lower than the melting point of the high melting point polyester fiber by 30 ° C. or more. The cushioning material manufacturing method according to claim 1, wherein the constituent core-sheath fibers and the non-heat-welding fibers are high melting point polyester fibers. 12. The coil spring is filled with each of mixed fibers in which the mixing ratio of the heat-welding fiber and the non-heat-welding fiber is changed to change the hardness depending on the site.
A method for manufacturing the described cushion material. 13. The method for producing a cushioning material according to claim 1, wherein the first fiber assembly is obtained by appropriately entangling and joining the fibers with a needle punch. 14. An array pocket coil body in which a plurality of pocket coil rows in which a plurality of pocket coils each containing one coil spring are continuous are arranged, and are integrally formed so as to cover each bag body. A heat-weldable fiber and a non-heat-weldable fiber, and a fiber-welded coating body having a joint formed by heat-welding the heat-weldable fiber. Cushion material to be used. 15. The cushioning material according to claim 14, wherein a hardness adjusting material having a lattice or a mesh is provided inside the fiber-welded molded body portion located on at least one of the upper surface and the lower surface of the coil spring. The cushioning material according to claim 13, wherein the cushioning material, the hardness adjusting material, the coil spring, and the fiber-welded molded body are integrally formed. 16. The cushion material according to claim 14, wherein (A) the heat-welding fiber or the heat-welding fiber is provided inside the fiber-welded molded article portion located on at least one of the upper surface and the lower surface of the coil spring. Or (B) heat-fusible fiber or heat-fusible resin powder admixed with or placed on the surface, or (C) a sheet-like fiber assembly containing the heat-fusible fiber is sewn on the surface, or A sheet-shaped or plate-shaped palm fiber aggregate having a joint portion formed by heat-welding the heat-weldable fibers in the sheet-shaped or plate-shaped palm fiber aggregate is arranged, and the palm fiber aggregate is The coil spring and the fiber-welded molded body are integrally formed. 17. A core made of low melting point polyester fiber, polyethylene fiber, polypropylene fiber, polyvinyl chloride fiber, nylon fiber, ethylene vinyl acetate copolymer fiber, and high melting point type polyester fiber, and the core. From the melting point of the high melting point polyester fiber
One or two of the adhesive core-sheath type fibers and the like, which are composed of a covering portion made of a thermoplastic resin having a low melting point of 0 ° C. or more
The cushion material according to claim 14, which is one or more kinds. 18. The heat-fusible fiber comprises a core made of a high melting point polyester fiber and a coating part made of a thermoplastic resin which covers the core and has a melting point lower than the melting point of the high melting point polyester fiber by 30 ° C. or more. The cushioning material according to claim 14, which is an adhesive core-sheath type fiber, and the non-heat-welding fiber is a high melting point type polyester fiber.