JPS61193613A - Production of mattress - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention (a) Industrial Application Field This invention relates to a method of manufacturing a mattress having a harder material inside than its surroundings. , those containing hard materials are being evaluated as being better for health and contributing to improving the strength of mattresses. Conventionally, in the manufacture of mattresses containing this type of hard material, the internal hard material and two soft foams laminated on both sides are separately molded, and then bonded together to form a single body. This was accomplished by

(c) Problems to be Solved by the Invention In order to provide a hard material in a soft foam, a process of separately molding each material is required, and it is also necessary to bond them together. In particular, when a hard material is used as a health mat and is profiled in a shape that alternately provides mountain-like unevenness on the front, back, left, and right sides, the adhesive surface does not adhere well, which is very troublesome. or,
If the hard material is profiled and the soft foam that adheres to the surface is flat, there will be point-like adhesion, which poses a problem in that the application of adhesive and the method of adhesion are extremely difficult.

(d) Means for Solving the Problems This invention provides a method for manufacturing a mattress in which a coating is formed on the upper surface of a lower foam made of a molded soft foam, and the molded soft foam is coated around the lower foam. Next, a foam stock solution is injected onto the coating, and an upper foam made of a molded flexible foam is provided to cover the foam stock solution, and then the foam stock solution is allowed to foam and harden. The present invention attempts to solve the above-mentioned problems by forming an inner foam that is integrated with the lower foam, the side foam, and the upper foam.

(E) Effect The foam stock solution injected onto the lower foam does not excessively impregnate into the lower foam because of the coating formed on the upper surface of the lower foam. At this time, the coating
If it is a film, etc., it can almost prevent the foam stock solution from impregnating the lower foam, and if the coating is nonwoven fabric, etc., the foam stock solution will moderately impregnate the lower foam, and it will improve the adhesiveness with the lower foam when the foam hardens. enhance Further, when the foam stock solution foams and hardens, the upper foam and the side foam are impregnated with a small amount and harden, so that they are bonded together.

(F) Example To explain the example of this invention based on the drawings, first, lower polyurethane foam (1)
A flexible polyurethane foam is formed into a rectangular shape with an appropriate thickness, and the upper surface is provided so as to be flat. A coating (2) is formed on its upper surface. The coating (2) is made by combining the hard polyurethane foam stock solution (3) described below with the lower polyurethane foam (
This material is used to prevent excessive impregnation of 1), and is made of a material with almost no impregnability, such as synthetic resin leather or film, or a material with moderate impregnability, such as nonwoven fabric. Next, side polyurethane foam (4) made of a similar flexible polyurethane foam is erected on the four sides around the lower polyurethane foam (1) and fixed with adhesive. The height of the side polyurethane foam (4) is the same as that of the lower polyurethane foam (1).
), there is only need to be a height that allows the inner polyurethane foam (9) and the upper polyurethane foam (5) to be laminated on top of the polyurethane foam (9).

Next, a rigid polyurethane foam stock solution (3) is injected onto the coating (2) of the lower polyurethane foam (1).

The rigid polyurethane foam stock solution (3) is adjusted so that it is even and flat on the lower polyurethane foam (1). This rigid polyurethane foam stock solution (3)
The amount is appropriate depending on the use of the mattress, but it is the amount that will adhere to the lower surface of the upper polyurethane foam (5) when the foam is cured. In addition, when manufacturing a tri-fold mattress, if the amount of hard polyurethane foam stock solution (3) for the mattress in the center is 100%, then the amount of stock solution (3) for the mattress on both sides should be 60 to 80%.
If you do this, the firmness and thickness of the tri-fold mattress will be ideal.

Next, an upper polyurethane foam (5) made of a flexible polyurethane foam is provided on the hard polyurethane foam stock solution (3) with a certain amount of space provided therein so as to cover the upper polyurethane foam (5). The lower surface of the upper polyurethane foam (5) is profiled with recesses (6) and protrusions (7) alternately provided on the left, right, front and back, but as another example,
The protrusions may be formed in a ridge shape. Furthermore, upper polyurethane foam (5) and side polyurethane foam (4)
) is provided outside the mold (8) to prevent the upper polyurethane foam (5) from lifting too much upwards due to foaming of the rigid polyurethane foam stock solution (3). Next, the rigid polyurethane foam stock solution (3) is heated and reacted for a certain period of time to foam and harden. At this time, the upper polyurethane foam (5) is lifted upward to some extent, but the upper limit is defined by the upper outer frame (8). At this time, the foamed rigid polyurethane foam stock solution (
3) is in close contact with the lower surface of the upper polyurethane foam (5) and the inner surface of the side polyurethane foam (4), but is not deeply impregnated. When the reaction is finished, the internal polyurethane foam (made of rigid polyurethane foam)
9) The upper surface forms an uneven surface corresponding to the uneven surface of the profile processing on the lower surface of the upper polyurethane foam (5), and is tightly adhered to the lower surface of the upper polyurethane foam (5). The side surfaces of the inner polyurethane foam (9) are likewise tightly adhered to the inner surfaces of the side polyurethane foam (4).

After the inner polyurethane foam (9) has been integrated with the upper, lower and side polyurethane foams (1), (4) and (5), the outer mold (8) is removed. Furthermore,
Outer packaging material (
10). The outer packaging material (lO) is made of a flexible material such as equivalent soft polyurethane foam, synthetic resin cotton, or wool. In addition to flexible polyurethane foam, foam rubber, polyethylene foam, polypropylene foam, vinyl acetate foam, etc. can be used as the flexible foams for the lower, upper, and side foams. The inner foam only needs to be harder than the lower and upper foams, and its material may include rigid polyurethane foam, semi-rigid polyurethane foam, and density 20 to 50 kg/min.
m3 flexible polyurethane foam or the like can be used.

(G) Effects of the Invention Since this invention has the above-described structure and function, the manufacturing process of a mattress that has soft foam on the top and bottom and an internal foam that is harder than the top and bottom in the middle can be made very easily and reliably. It has the effect of being able to be carried out. Furthermore, even if the adhesion surface between the internal foam and the soft foam has a complicated shape with irregularities such as profile processing, the adhesive can be reliably bonded without using an adhesive. Furthermore, by changing the amount of the foam stock solution in the internal foam and the thickness of the soft foam, it is possible to easily obtain a mattress having a hardness and thickness suitable for the intended use.

[Brief explanation of drawings]

Embodiments of the present invention are shown, and FIG. 1 is a cross-sectional view of a mattress manufactured by the manufacturing method of the present invention, and FIGS. 2 to 5 are cross-sectional explanatory views sequentially showing manufacturing steps. ■... Lower polyurethane foam, 2... Film, 3... Rigid polyurethane foam stock solution, 4... Side polyurethane foam, 5... Upper polyurethane foam, 6... Profile processing recess, 7. ...Profile processing convex portion, 8...Outer frame, 9...Internal polyurethane foam (rigid polyurethane foam) lO...Outer packaging material.

Claims (4)

[Claims] (1) A coating is formed on the upper surface of a lower foam made of a molded soft foam, a side foam made of a molded soft foam is provided around the lower foam, and then a lower foam, After injecting the foam stock solution for the inner foam, which is harder than the upper foam, and placing the molded upper foam made of soft foam so as to cover the foam stock solution, the foam stock solution is foamed and hardened to form the lower foam and side parts. A method of manufacturing a mattress, comprising forming an inner foam that is integrated with a foam, an upper foam. (2) The method for manufacturing a mattress according to claim 1, wherein the flexible foam is a flexible polyurethane foam. (3) The method for manufacturing a mattress according to claim 1 or 2, wherein the foam stock solution is a rigid polyurethane foam stock solution. (4) The method for manufacturing a mattress according to any one of claims 1 to 3, wherein the upper foam has irregularities on its lower surface.