KR102636288B1 - cushion assembly and manufacturing metho thereof - Google Patents

Abstract

Disclosed is a cushion assembly and its manufacturing method.
A cushion assembly according to an embodiment includes an elastic plate material having elasticity and forming a plurality of fitting holes; It may include a plurality of elastic members fitted into the plurality of fitting holes.

Description

Cushion assembly and manufacturing method thereof}

It relates to a cushion assembly provided to provide cushioning force to the interior of a bed mattress, sofa, chair, etc., and a method of manufacturing the same.

A cushion assembly may be built into a bed mattress, sofa, chair, etc. to provide cushioning force.

Cushion assemblies are mainly made by combining a plurality of coil springs using Heller curl coils, or by inserting a plurality of coil springs individually into pockets and bonding the pockets together.

Cushion assemblies using double helical coils have a high risk of causing excessive contact noise between the coil springs and helical coils, and as the period of use elapses, the helical coils are easily deformed, making it difficult to maintain a stable connection between the coil springs. You can lose.

Also, in the case of a cushion assembly using pockets, there is a high risk of frictional noise between the pockets being caused, and the adhesion between the pockets can easily deteriorate as the period of use elapses.

In addition, since these cushion assemblies are manufactured by individually connecting coil springs with helical coils or connecting pockets into which coil springs are inserted one by one, they have a disadvantage in terms of productivity improvement.

The object is to provide a cushion assembly and a manufacturing method thereof that can effectively suppress noise generation.

The object is to provide a cushion assembly and a method of manufacturing the same that can effectively extend its service life.

The object is to provide a cushion assembly and its manufacturing method that can effectively improve productivity.

The object of the present invention is to provide a cushion assembly and a method of manufacturing the same that can effectively set the cushion force differently for each part.

A cushion assembly according to an embodiment of the present invention includes an elastic plate material having elasticity and forming a plurality of fitting holes; It may include a plurality of elastic members fitted into the plurality of fitting holes.

At least one of the plurality of elastic members may have an elastic force different from the rest.

The material of the elastic plate may include at least one of rubber, latex, and synthetic resin foam, and the elastic member may include a coil spring formed through a light steel wire and heat treated.

The elastic member includes: a coil spring inserted into the fitting hole so that the outer circumference is supported by the inner periphery of the fitting hole; It may include an insert inserted inside the coil spring.

At least one of the plurality of coil springs may have an elastic force different from the rest, and at least one of the plurality of inserts may have an elastic force different from the rest.

The fitting hole may be formed on one surface of the elastic plate along the thickness direction of the elastic plate, and the depth of the fitting hole may be shallower than the thickness of the elastic plate.

The fitting hole may further include a blocking plate that penetrates the elastic plate in the thickness direction and is coupled to the other surface of the elastic plate to close one end of the plurality of fitting holes.

Additionally, according to one aspect, the method of manufacturing a cushion assembly according to an embodiment of the present invention includes forming the elastic plate material; Including assembling the elastic member into the fitting hole of the molded elastic plate, wherein molding the elastic plate includes at least one of rubber, latex, and synthetic resin in a molding space corresponding to the shape of the elastic plate. It may include foaming and injection molding with a mold provided.

According to another aspect, the method of manufacturing a cushion assembly according to an embodiment of the present invention includes forming the elastic plate material; Including assembling the elastic member into the fitting hole of the molded elastic plate, wherein forming the elastic plate includes a plurality of sleeve-shaped perforation tools corresponding to the shape of the fitting hole, and an arrangement structure of the fitting holes. Prepare wooden blocks arranged to correspond to; To form the elastic plate, prepare a material plate having the same thickness as the elastic plate; It may include pressing between the raw material plate and the wood board using a press so that the plurality of inserting holes are perforated in the raw material plate using the plurality of punching tools.

In addition, a cushion assembly according to another embodiment of the present invention includes a first elastic plate having elasticity and having a fitting groove formed in a partial area of one surface; It may include a second elastic plate that has an elastic force different from that of the first elastic plate, is fitted into the fitting groove, and has one surface exposed to the outside of the fitting groove forming the same plane as the one surface of the first elastic plate. there is.

The second elastic plate may have a plurality of fitting holes and may further include a plurality of elastic members fitted into the plurality of fitting holes.

According to the cushion assembly and its manufacturing method according to an embodiment, noise caused by the cushion assembly can be effectively suppressed.

According to the cushion assembly and its manufacturing method according to an embodiment, the service life of the cushion assembly can be effectively extended.

According to the cushion assembly and its manufacturing method according to an embodiment, the production line of the cushion assembly can be effectively improved.

According to the cushion assembly and its manufacturing method according to one embodiment, it is possible to effectively set the cushion force differently for each part of the cushion assembly.

Figure 1 is a perspective view of the main part of a cushion assembly according to one embodiment.
Figure 2 shows the lower part of the mattress on which the cushion assembly is installed according to one embodiment in a cut state.
Figure 3 is a cross-sectional view showing the main structure of a mattress on which a cushion assembly is installed according to one embodiment.
Figure 4 shows the manufacturing process of the elastic plate in the cushion assembly according to one embodiment.
Figure 5 shows a modified example of a wood board used in manufacturing an elastic board of a cushion assembly according to an embodiment.
Figure 6 is a main cross-sectional view showing a modified example of a cushion assembly according to an embodiment.
Figure 7 is a main cross-sectional view showing another modification of the cushion assembly according to one embodiment.
Figure 8 is a perspective view of a cushion assembly according to another embodiment.
Figure 9 is an exploded view of the cushion assembly shown in Figure 8.
Figure 10 shows a modified example of a cushion assembly according to another embodiment.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. The embodiments introduced below are provided as examples so that the idea of the present invention can be sufficiently conveyed to those skilled in the art. The present invention is not limited to the embodiments described below and may be embodied in other forms. In order to clearly explain the present invention, parts not related to the description are omitted from the drawings, and in the drawings, the width, length, thickness, etc. of components may be exaggerated for convenience. Like reference numerals refer to like elements throughout the specification.

As shown in Figures 1 to 3, the cushion assembly 10 according to one embodiment is installed to exert cushioning force on the bed mattress 1, material, topper, sofa, chair, etc., and is made of an elastic plate. (20) and a plurality of elastic members (30) assembled to the elastic plate (20).

The elastic plate 20 may be prepared in a plate shape using a material having elasticity. The elastic plate 20 may be made of materials such as rubber, latex, synthetic resin foam, etc. so that it can exert its own elasticity.

Synthetic resin foam can be prepared by foaming and molding any one of synthetic resins such as ABS, polyurethane, polyethylene, EVA, and PVC.

In addition, the elastic plate 20 has little risk of noise generation during elastic deformation, and can be made of various materials not mentioned above within the range of effectively performing a cushioning action for shock relief.

A fitting hole 21 is formed in the elastic plate 20, and the fitting hole 21 can perform a damping action through internal air. A plurality of inserting holes 21 may be provided to be evenly distributed throughout the elastic plate 20. The plurality of fitting holes 21 may be arranged to form a grid.

The fitting hole 21 may be provided in various shapes, including a circle, a polygon such as a square or pentagon, and an oval, within a range that can stably support the elastic member 30 in a state in which movement is prevented. The fitting hole 21 may be provided to correspond to the shape of the elastic member 30.

The elastic member 30 is assembled to be accommodated in the fitting hole 21 and performs a cushioning action, thereby improving the damping performance of the fitting hole 21 and contributing to improving the overall cushioning performance of the elastic plate 20. .

The elastic member 30 may include a coil spring 31. The coil spring 31 may be formed from light steel wire and heat treated to enhance strength. The light steel wire constituting the coil spring 31 may have a diameter of 0.2 to 2.9 mm.

The fitting hole 21 may be provided in a circular shape corresponding to the shape of the coil spring 31.

In this cushion assembly 10, the elastic plate 20 itself causes almost no noise, and since contact between the coil springs 31 inserted into the fitting hole 21 is blocked, noise is generated when performing the cushioning function. There is little risk of causing .

In addition, rubber, latex, and synthetic resin foams can maintain their elasticity stably for a long period of time, and heat-treated light steel wire can be used for a long period of time without fear of corrosion.

Therefore, according to the material characteristics of the elastic plate 20 and the elastic member 30 described above and the arrangement structure of the coil springs 31 constituting the elastic member 30, the cushion assembly 10 exhibits smooth cushioning performance. It is possible to maintain a stable state for a longer period of time.

The configuration of the elastic member 30 is not limited to the coil spring 31. The elastic member 30 may have various shapes and structures within the range of providing a cushion when assembled in the fitting hole 21.

For example, the elastic member may include a coil spring 31 inserted into a pocket (not shown), and even in the case of this elastic member, noise is generated due to contact between the elastic members and the pocket (not shown). can be prevented.

The fitting hole 21 is formed to penetrate the elastic plate 20 in the thickness direction, and the cushion assembly 10 is a blocking plate 40 coupled to the other side of the elastic plate 20 to close one end of the fitting hole 21. ) can be further provided. The blocking plate 40 can be coupled to the elastic plate 20 to close the lower ends of the fitting holes 21.

The blocking plate 40 is made of the same material as the elastic plate 20, such as rubber, latex, synthetic resin foam, silk, or sponge, and is attached to one side of the elastic plate 20 through an adhesive such as hot melt. You can.

Meanwhile, the elastic plate 20 can be molded by foaming and injecting at least one of rubber, latex, and synthetic resin into a mold having a molding space corresponding to the shape of the elastic plate 20.

Therefore, the cushion assembly 10 is a simple process of assembling the foam-molded elastic plate 20 by adhering the blocking plate 40 and inserting the elastic members 30 into the fitting holes 21 of the elastic plate 20. It can be manufactured through , which can have an advantage in terms of productivity.

Additionally, as shown in FIG. 4, the elastic plate 20 can be easily manufactured through simple perforation processing.

As shown in FIG. 4, at this time, a plurality of sleeve-shaped perforation tools 110 corresponding to the shape of the fitting holes 21 are arranged to correspond to the arrangement structure of the fitting holes 21, a wood board 100, and an elastic board. In order to form (20), the elastic plate 20 can be prepared using a material plate 200 having the same material and thickness as the elastic plate 20.

The wood board 100 can be prepared by processing general wood, MDF (Medium Density Fiber Board), LPM (Low Pressure Melamine impregnated paper), PB (Particle Board), etc. into a flat plate shape.

The perforation tool 110 is made of a hard metal material, and a perforation blade may be provided at the top of the perforation tool 110.

An annular support groove 101 corresponding to the shape and size of the cross section of the perforation tool 110 is provided on the upper surface of the wooden board 100, and the lower end of the perforation tool 110 is inserted into the support groove 101. 100), movement on the wooden board 100 can be prevented when the insertion hole 21 is drilled.

When the wood board 100 and the raw material 200 are prepared, as shown in FIG. 4, a press is used so that a plurality of inserting holes 21 are simultaneously drilled into the raw material 200 using a plurality of punching tools 110. 300) can be used to pressurize between the material plate 200 and the wood plate 100.

In FIG. 4, symbol 310 indicates a lower support part of the press 300 that supports the lower surface of the wood board 100, and symbol 320 indicates an upper support part of the press 300 that supports the upper surface of the raw material 200. .

The upper support part 320 and the lower support part 310 of the press 300 move in the direction facing each other in such a way that one is fixed and the other moves, or the two move together, and the material plate 200 and The space between the wooden boards 100 can be pressed.

As the space between the material plate 200 and the wood board 100 is pressurized, the plurality of perforation tools 110 penetrate the material plate 200 and form a plurality of inserting holes 21 in the material plate 200 at the same time, Accordingly, the material plate 200 can be formed into an elastic plate 20 through a simple perforation process.

In the manufacturing process of such an elastic plate 20, an inexpensive wooden board 100 and a perforation tool 110 are used without the need to use a mold made of metal or having a molding space corresponding to the shape of the elastic plate 20. By applying a method of perforating the raw material plate 20, the manufacturing cost of the elastic plate 20 can be significantly reduced.

In addition, in the case of the wooden board 100, it is easy to process the support groove 101, and one wooden board 100 can be used to process insertion holes 21 of various sizes.

As shown in FIG. 5, a plurality of support groove groups 101G for supporting the punching tool 110 are arranged in a lattice shape on the wooden board 100′, and each support groove group 101G has different diameters. It may be configured to include a plurality of concentric support grooves (101a, 101b, 101c).

According to this, when manufacturing the elastic plate 20, the worker uses the perforation tool 110 corresponding to the diameter of the insertion hole 21 of the desired size to support grooves 101a, 101b, and 101c of the wood plate 100 corresponding to the size. ) It is possible to manufacture elastic boards 20 with various sizes of fitting holes 21 using a single wooden board 100 by applying a method of fixing them so that they are supported on.

The manufactured cushion assembly 10 can be installed to be inserted into the outer shell 2 of a mattress 1, a mattress, a topper, a sofa, or a chair. Here, chairs may include general chairs as well as those used as seats in transportation vehicles such as cars and trains.

An upper finishing plate 3 and a lower finishing plate 4 may be further installed on the upper and lower parts of the cushion assembly 10 located inside the outer shell 2, respectively. The upper finishing plate (3) and the lower finishing plate (4) may each be composed of a single ply or multiple ply.

The upper finishing plate (3) and the lower finishing plate (4) are auxiliary cushion layers and are made of materials such as rubber, latex, synthetic resin foam, silk, sponge, etc., the same as the material of the elastic plate 20, and are made of materials such as hot melt. It can be attached to the elastic plate 20 or the blocking plate 40 through an adhesive.

The fitting hole 21 of the elastic plate 20 is blocked to the top by the upper finishing plate 3, allowing the air damping action to be performed more effectively.

Meanwhile, in order to obtain a cushion assembly that provides different cushioning force for each zone, the plurality of elastic members 30 assembled to the elastic plate 10 may be provided so that at least one has an elastic force different from the rest.

In this case, elastic members 30 with different elastic forces can be prepared by varying the diameter of the light steel wire forming the coil spring 31 or the heat treatment conditions of the coil spring 31.

At least two types of elastic members 30 with different elastic forces are provided, and the cushion assembly 1 adjusts the arrangement structure of the elastic members 30 with different elastic forces so that at least two or more areas have different cushion forces. Arrangements can be made to provide.

For example, when the cushion assembly 10 is employed in the mattress 1, the cushion assembly 10 has a first area and a second area at both ends in the longitudinal direction of the mattress 1, and a third area between them. It can be arranged to provide different cushioning forces. And the fitting hole 21 of the elastic plate 20 corresponding to the third area is harder than the elastic member 30 assembled in the fitting hole 21 of the elastic plate 20 corresponding to the first and second areas. The elastic member 30 can be assembled. Therefore, the cushion assembly 10 provides a relatively softer cushioning to the user's lower back supported in the third area than to the user's head and legs supported in the first and second areas of the mattress 1. You can support your lower back more effectively.

As shown in Figure 6, which shows a variation of the cushion assembly 10, the elastic member 30 includes a coil spring 31 inserted into the fitting hole 21 so that the outer circumference is supported on the inner periphery of the fitting hole 21, and , It may be configured to include an insert 32 inserted inside the coil spring 31.

The insert 32 may be made of rubber, latex, or synthetic resin foam, the same material as the elastic plate 20.

The elastic insert 32 is mounted in the fitting hole 21 together with the coil spring 31 to increase the damping performance of the fitting hole 21 and contribute to improving the overall cushioning performance of the elastic plate 20. You can.

The insert 32 may be provided in the form of a hollow pillar so that it can perform an air damping action on its own.

In addition, in the case of the cushion assembly 10A according to the present modification, at least one of the plurality of coil springs 31 has an elastic force different from the rest, and at least one of the plurality of inserts 32 has an elastic force different from the rest. It can be arranged to do so.

At this time, the coil springs 31 can be provided with different elastic forces by varying the diameter of the light steel wire or the heat treatment conditions. In addition, the insert 32 can be prepared with different elastic forces by varying the density of the material.

According to this, the cushion assembly 10A mixes coil springs 31 with different elastic forces and inserts 32 with different elastic forces, so that a variety of zones with different cushioning forces are provided, and each zone The difference in cushioning power provided can be further refined.

As shown in FIG. 7 showing another modification of the cushion assembly 10, the fitting hole 21' is formed on one surface of the elastic plate 20' along the thickness direction of the elastic plate 20', and the fitting hole (21') The depth (t2) of the elastic plate (21') may be shallower than the thickness (t1) of the elastic plate (20').

According to the structure of this fitting hole (21'), the elastic plate (20') has a structure in which the lower part of the fitting hole (21') is closed even when the separate blocking plate (40) is removed, so that the fitting hole (21') It is possible to prevent the elastic member 30 assembled in from being separated from the elastic plate 20'. Accordingly, the cushion assembly 10B can have a simplified configuration by eliminating the blocking plate.

The elastic plate 20' according to this modification can be molded by foaming and injecting at least one of rubber, latex, and synthetic resin into a mold having a molding space corresponding to the shape of the elastic plate 20.

In order to easily remove the elastic plate 20' on which the foam injection molding has been completed from the molding space, the fitting hole 21' may be provided so that the diameter of the upper part where the opening is formed is larger than that of the lower part, or the diameter increases toward the upper part. there is.

In addition, as shown in FIGS. 8 and 9, the cushion assembly 10C includes a first elastic plate 50 having elasticity and a fitting groove 51 formed in a partial area of one surface, and a first elastic plate 50. ) and may be provided with a second elastic plate 60 that has an elastic force different from that and is fitted into the fitting groove 51.

At this time, the second elastic plate 60 is provided so that one upper surface exposed to the outside of the fitting groove 51 is flush with the upper one surface of the first elastic plate 50, so that the upper surface of the cushion assembly 10 is flat as a whole. It can be achieved.

The first elastic plate 50 and the second elastic plate 60 are provided to exert their own elasticity through materials such as rubber, latex, synthetic resin foam, etc., and the first elastic plate 50 and the second elastic plate ( 60) can have different elastic forces depending on the type of material or difference in density.

Such a cushion assembly (10C) can be prepared to provide different cushioning sensations in at least two large areas by using a first elastic plate 50 and a second elastic plate 60 with different elastic forces.

For example, when the cushion assembly 10C is employed in the mattress 1, the second elastic plate 60 is provided on one side of the cushion assembly 10C in the width direction to occupy approximately half of the cushion assembly 10C. It can be.

Therefore, when the mattress 1 is provided in a size for two people, two users lying on both sides of the mattress 1 in the width direction can be provided with different cushioning sensations.

At this time, the second elastic plate 60 provides a seat for one user to lie down, and the first elastic plate 50 on one side of the second elastic plate 60 provides a seat for another user to lie down. , the first elastic plate 50 on the periphery of the second elastic plate 60 may serve as a frame supporting the circumference of the second elastic plate 60.

In addition, two users who want to receive a softer cushion feel can select a lying position according to the desired cushioning by selecting the softer one of the first elastic plate 50 and the second elastic plate 60 and lying down. There will be.

In addition, as shown in FIG. 10, the second elastic plate 20 is provided with a plurality of fitting holes 21, and the cushion assembly 10C includes a plurality of elastic members fitted into the plurality of fitting holes 21. 30) can be arranged to further include.

That is, the second elastic plate 20 has the same structure as the elastic plate 20 in the above-described embodiment and can be provided to improve overall cushioning performance through the fitting hole 21 and the elastic member 30.

10: Cushion assembly 20: Elastic plate
21: Fitting hole 30: Elastic member
31: coil spring 40: blocking plate

Claims (11)

delete delete delete delete delete delete delete delete A method of manufacturing a cushion assembly comprising an elastic plate material having elasticity and formed to penetrate a plurality of fitting holes, and a plurality of elastic members fitted into the plurality of fitting holes,
Forming the elastic plate;
Including assembling the elastic member by inserting it into the fitting hole of the molded elastic plate,
Forming the elastic plate includes:
preparing a wood board in which a plurality of sleeve-shaped perforation tools corresponding to the shape of the fitting hole are arranged to correspond to the arrangement structure of the fitting holes;
To form the elastic plate, prepare a material plate having the same thickness as the elastic plate;
It includes: pressing between the raw material plate and the wood board using a press so that the plurality of inserting holes are perforated in the raw material plate by the plurality of punching tools,
A plurality of support groove groups for supporting the perforation tool are arranged on the wooden board to form a grid,
Each support groove group includes a plurality of concentric support grooves having different diameters,
Preparing the woodblock includes:
A method of manufacturing a cushion assembly comprising inserting and fixing the lower end of the perforation tool corresponding to the diameter of the fitting hole into any one of a plurality of support grooves forming the support groove group. delete delete

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