JPS62159690A - Cushion - 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 [Technical Field of the Invention] The present invention relates to a cushion formed by stuffing short fibers into a bag-like side fabric.

[Prior art and its problems]

From an ergonomic standpoint, a firm cushion made of fiber-filled material will cause less fatigue than a soft one.
Improves the comfort of sleeping and sitting.

By the way, conventional cushions made of fiber-filled cotton material are generally made by folding a web sheet created by the carded web method into a flat shape to form a cotton layer, and stuffing this into a bag-like side fabric. be. However, in cushions made in this way, the short fibers are oriented along the flat direction of the bag-like side material, so the compression ratio against the force applied in the thickness direction is relatively large, and the cotton layer is not sufficient. It is not possible to obtain firmness. Therefore, it has not been satisfactory to obtain a sleeping or sitting comfort that does not cause fatigue. Also,
The cotton layer tends to sag or sag due to repeated use, and its morphological stability is also unsatisfactory. In addition, because the cotton layer is not sufficiently hard, the quilt and binding parts that fix the bag-like side material and the cotton layer are easily dented and deep grooves are formed, resulting in poor appearance. There was a problem in that the quilting and binding gave a sense of discomfort to the human body.

In order to improve this problem, a cotton filling method using an air blowing method has been proposed. The stuffed material obtained by this method has short fibers stuffed into a thin bag-like side material, and the short fibers form a large number of thin layers along a plane substantially perpendicular to the flat direction of the bag-like side material. It has a fiber filling structure in which the short fibers are arranged randomly within each thin layer, and are stacked in layers in the flat direction. Therefore, the compression rate in the thickness direction is small, and when used as a cushion, it has the effect of being able to be made into a hard fiber stuffed material with great resilience.

By further applying quilting or binding to this fiber stuffed material, a more durable and comfortable cushion can be obtained than that obtained using the carded web method.

However, even with this air suction method, the quilting and binding processes must be performed after filling the inside of the bag-shaped side fabric, so it is not suitable for thick cushions or cushions whose thickness changes midway. Not only is this method difficult to apply, but it is also necessary to provide densely quilted portions or binding portions in order to stabilize the stuffed material. Furthermore, depending on the purpose and form of use of the cushion, or when performing special binding, it is not possible to perform a binding process afterwards, which has the disadvantage that there are considerable restrictions on the use and development of the cushion.

[Purpose of the invention]

In view of the above-mentioned problems, the purpose of the present invention is to reduce the compression ratio in the thickness direction by devising the filling of short fibers into the bag-like side material, thereby making the filling firmer and preventing the cotton layer from collapsing. The product has a good appearance, the quilting and binding do not make the human body feel uncomfortable, and it provides comfortable sleeping and sitting comfort, thereby expanding the range of applications. It is about providing.

[Structure of the invention]

The present invention has the following configuration to achieve the above object. That is, in the cushion of the present invention, a large number of short fibers packed into the bag-like side fabric form a thin layer randomly arranged along a plane substantially perpendicular to the plane direction of the bag-like side fabric, and Is the stuffed material made of a large number of thin layers stacked in the plane direction, and at least a part of the thin layers is interrupted in continuity near the staples or gussets provided in the bag-like side fabric? , or is characterized by having a disordered shape. More simply, it is characterized by a cushion made of cotton stuffing, which is formed by providing a binding thread in advance on the bag-like side material or providing a gusset inside, and blowing short fibers together with an air flow into the bag-like side material. It is something to do.

The inventors of the present invention have recognized that the characteristics of the cotton stuffed material produced by the air blowing method described above are optimal for use as a cushion. I learned that it is necessary to increase durability, and that a binding and quilting are necessary for this purpose. However, if these quilting and binding processes were performed after forming the batting as in the past, it would be unsuitable for the above-mentioned usage limitations and special processing. It was discovered that there is a drawback that the binding part must be tightly sealed.

The present invention solves this problem by providing a binding thread or a gusset cloth on the bag-like side material and blowing the short fibers into the bag-like side material when blowing the short fibers into the bag-like side material together with an air flow. Settled.

FIG. 1 shows an example of a bag-shaped side material provided with binding threads. −・−・、
2 are provided so as to cross the top and bottom, and the bag-like side fabric l provided with such binding threads 2 is set with its opening 7 at the tip of a short fiber blowing nozzle 6, and is A large number of short fibers 3 are blown into the bag-like side fabric 1 together with compressed air. Further, Fig. 2 shows the case of a bag-shaped side fabric provided with gussets, and the bag-shaped side fabric l is provided with gussets 4 in advance in several places so as to cross vertically, as in the case of binding thread. . Short fibers 3 are blown with compressed air into the bag-like side fabric l provided with such a gusset 4, as in the case of FIG. In the case of a bag-like side fabric provided with this gusset, it is desirable that the longitudinal direction of the gusset 4 is along the air flow, as shown in FIG.

In the present invention, a predetermined length of binding thread or gusset fabric is provided in advance in a slack state within the empty bag-like side fabric, so the quilting method is not practical. The binding thread 2 may be attached to a plurality of locations by setting a predetermined length using an appropriate method, and the length of the binding thread at each location does not necessarily have to be constant. The interval l between adjacent staple threads may be within 150 cn1 at one location (and can be set wider than the conventional staple thread interval. The staple thread 2 may be single-stitched or loop-stitched.

In addition, when providing the gussets 4, the weaving method may be used (or the sewn reverse method may be used.The length of the gussets 4 may be arbitrary, but the spacing should be 5 cm or more. 30
Preferably within cm.

When the gusset 4 is provided, it is desirable to provide it parallel to the air blowing direction as shown in FIG.

Furthermore, any conventionally known method may be used to blow the short fibers into the bag-like side fabric 1 using an air stream.

As the short fibers used in the present invention, any of synthetic fibers such as polyester, polyacrylic, polyamide, and polypropylene, natural fibers such as cotton, hemp, silk, and wool, or a blend of synthetic fibers and natural fibers can be used. However, it is particularly preferable to use fibers with low entanglement. In the case of mixed fibers, adhesive fibers containing a low melting point component may also be used. Among these fibers used, polyester is the most preferred material because of its excellent compression properties.

The length of the short fibers used is preferably 30 to 80 m/m, but it is desirable to use short fibers having a length shorter than the thickness of the cotton stuffing.

Further, according to the present invention, short fibers can be stuffed into the bag-like side fabric by freely changing the thickness and basis weight. Therefore, it is possible to easily obtain a cushion with a basis weight that suits the purpose and use of the cushion.

For example, FIGS. 3 and 4 each show the case where short fibers 3 are blown into a bag-like side fabric 1 having the same single binding yarn 2, but FIG. 4 is different from FIG. 3. This is a case where the basis weight is set to be very large. Also, Figures 5 and 6
Figure, same (bag-shaped side fabric 1 with binding thread 2 from binding)
6 shows the case where short fibers 3 are blown into the material, and FIG. 6 shows the case where the fabric weight is designed to be much larger than that in FIG. 5.

The cotton stuffing formed as described above generally has the following internal structure. That is, Figs. 2 and 7 to 9 show the cotton filling 20 obtained as described above, in which the short fibers 3 form a large number of scale-like thin layers 9 consisting of small units in the bag-like side fabric 1, A laminate 10 is formed by stacking a large number of thin layers 9, and the laminate 10 is filled into a bag-like side fabric l.

The short fibers 3 in one thin layer M9 are randomly arranged in the plane of the layer, as shown in FIG. In addition, the boundary surface between adjacent thin layers 9°9 has an annual ring shape centered on arrow G as shown in Fig. 7 in plan view, and a bag shape in side view as shown in Fig. 8. shape side area 1
The relationship is almost perpendicular to the flat direction. The interface between the thin layers 9 is not clearly visible because the short fibers 3 randomly arranged in the layers are partially entangled between adjacent layers. However, when the laminate 10 is pulled in opposite directions in the flat direction, the thin layers 9.9 are separated at the interface. On the other hand, even if the same operation is performed in the thickness direction, the separation location is not constant, and moreover, a larger force is required.

By the way, in the cushion of the present invention, the binding thread 2 is
Since the short fibers 3 were blown in with the gusset fabric 4 attached to the bag-like side fabric 1, the short fibers 3 were interfered with by these binding threads 2 and the gusset fabric 4, and the short fibers 3 were blown into the downstream side of the air flow. , the shape of the thin layer 9 is not completely shaped like an annual ring, and the continuity of the thin layer 9 is interrupted or the shape is disturbed in the binding thread 2 and its vicinity, or the gusset 4 and its vicinity, thin layer 9
The shape is difficult to distinguish, as shown by 9', or it is in a mixed state.

However, the presence of such disordered portions 9' is small as a whole, and has little effect on the entire cushion body. On the contrary, this disorder has the effect of preventing the cotton from shifting in the prior art, and makes it possible to increase the interval 1 between the staple threads and the interval between the gussets.

When the stuffed material 20 thus obtained is made into a cushion with a combination structure in which it is polymerized with a foam sheet 30 made of polyurethane or the like as shown in FIG. It can be made into something excellent.

[Function and effect of the invention]

Since the present invention has the above-described configuration, the effects of the air-blown cotton filling material are maintained, and as described above, cushions of any shape or form can be easily manufactured. In addition, it can be used with special binding and gusset types, so you can create cushions with excellent durability and appearance. Furthermore, it can be applied to automobile seats and the like by making the cushion bonded to a foam sheet in advance. In addition, the present invention can be applied to items that require a binding portion in advance, or to attach batting integrally to the back side of a seat cover that has a binding portion in advance, so the range of applications can be expanded.

A cushion having such a structure cannot be manufactured using the conventional back-stitching or back-quilting methods, and is particularly impossible to manufacture using the carded cotton method.

[Example] Polyester short fibers of 5 d x 51 m/m were used as raw cotton, and while being opened by an air blowing method, the opened short fibers were made into a bag-shaped side material with a width of 50 cm x a length of 50 cm and a thickness of 5 cm. 60 in the one with 6 binding threads at intervals.
A cushion body was obtained by packing 0 g.

Next, this cushion has a density of 20g/It and a thickness of 1O
It was layered on a cI11 polyurethane foam sheet to make a chair cushion body. The resulting cushion body has a good appearance and feel, has high compression elasticity in the thickness direction (the binding part does not give any discomfort to the body, and the cotton layer has little collapse even after repeated use, and has good form stability. , it was comfortable to sleep on.

[Brief explanation of drawings]

Figures 1 and 2 are schematic diagrams showing an example of the method for manufacturing the cushion of the present invention, and Figures 3 and 4 are explanatory diagrams showing differences in the amount of short fibers packed into the cushion of the present invention, respectively. , FIG. 5 and FIG. 6 are explanatory diagrams showing differences in the amount of short fiber stuffing according to other examples, FIG. 7 is a cross-sectional view showing an example of the cushion according to the present invention, and FIG. 9 is a sectional view taken along the line CC in FIG. 7, and FIG. 10 is a perspective view showing a mode in which the cushion of the present invention is combined with a foam sheet. l... Bag-shaped side fabric, 2... Binding thread, 3... Short fiber,
4...gusset cloth, 6...blow nozzle, 9...thin layer,
9'... Disturbed portion of thin layer, 10... Laminated body.

Claims (1)

[Scope of Claims] 1. A large number of short fibers packed in the bag-like side fabric form a thin layer randomly arranged along a plane substantially perpendicular to the plane direction of the bag-like side fabric, Is the stuffed material made of a large number of thin layers stacked in the plane direction, and at least a part of the thin layers is interrupted in continuity near the staples or gussets provided in the bag-like side fabric? , or a cushion characterized by having a disordered shape. 2. The cushion according to claim 1, wherein the batting material is formed by blowing short fibers together with an air flow into a bag-like side material which has a binding portion or a gusset inside.