JP2799274B2 - Mattress device and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mattress device formed by laminating a padding on a spring unit, and covering the laminated body with an exterior body, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In general, a mattress device has a spring unit formed by connecting a large number of coil springs in a matrix, and a padding such as synthetic cotton or urethane foam is laminated on the spring unit. . This laminate is covered with an exterior body formed of a mirror portion and a town portion.

In the mattress device having such a configuration, the padding is connected and fixed to the spring unit with a large number of clips in order to prevent the padding from moving relative to the spring unit. Further, in order to prevent the exterior body from moving relative to the spring unit, one end is connected and fixed to the inner surface of the mirror unit to provide a flange cloth, and the other end of the flange cloth is provided around the spring unit. Like the padding, the clip is connected and fixed.

According to such a configuration, the padding is prevented from being displaced by the clip and the flange cloth, and the exterior body is prevented from being displaced by the flange cloth.

[0005] However, the operation of connecting the padding to the spring unit with a large number of clips requires a great deal of time and labor, which may lead to a decrease in productivity. In addition, the flange cloth is connected by the spring unit. That work also takes a lot of trouble.

On the other hand, in the case where the mattress device has been damaged due to long-term use and must be discarded, recently, the waste cannot be collected unless it is discarded for each type of material. In many areas, collection systems are used. When the mattress device is discarded in an area where the sorting and collection is being performed, the spring unit, which is a metal part, and the padding and the outer casing made of synthetic fiber or the like must be discarded separately.

In this case, if the padding is connected to the spring unit by a large number of clips, it is not easy to remove the padding from the spring unit, and similarly, it is not easy to remove the outer package from the spring unit. Therefore, the disassembly work at the time of disposal may take a lot of trouble.

[0008]

As described above, in the conventional mattress device, the padding is connected to the spring unit with a large number of clips, and the exterior body is also connected to the spring unit with a clip via the flange cloth. In some cases, the assembling operation takes a lot of time, and when it is necessary to disassemble each material at the time of disposal, the assembling operation takes time.

The present invention has been made in view of the above circumstances, and an object of the present invention is to allow a padding and an outer package to be held and fixed to a spring unit without using a large number of clips, and to be easily disassembled. And a method for manufacturing the same.

[0010]

According to the present invention, there is provided a mattress device comprising: a spring unit having an upper surface and a lower surface;
An outer package body having at least an upper portion of the spring unit, a mirror portion covering at least the upper surface of the laminate of the stuffer and the spring unit, and a gusset covering the outer peripheral surface; and an inner peripheral portion of the mirror portion A flange cloth provided with one end connected to the portion, and a heat-shrinkable synthetic resin formed over the entire outer peripheral surface of the spring unit and holding the other end of the flange cloth. A connection member for fixing the flange cloth to the spring unit.

A method of manufacturing a mattress device according to the present invention is a method of manufacturing a mattress device in which a laminate in which at least upper surfaces of upper and lower surfaces of a spring unit are stuffed is covered with an exterior body having a mirror portion and a gusset portion. A step of laminating the padding on at least the upper surface of the spring unit, a step of connecting one end of a flange cloth to an inner peripheral part of the mirror part, and a step of covering the entire outer peripheral surface of the spring unit and the other part of the flange cloth. Providing a connecting member made of a heat-shrinkable synthetic resin while holding the end portion,
Heating the connection member to shrink it to fix the other end of the flange cloth to the spring unit.

[0012]

According to the above construction, at the time of assembling, the connecting member provided over the entire outer peripheral surface of the spring unit and holding the other end of the flange cloth is contracted by heating, so that the other end of the flange cloth is heated. The part can be fixed to the spring unit by the connecting member. When the flange cloth is fixed to the spring unit, the exterior body and the padding can be fixed to the spring unit via the flange cloth. When disassembling, just cut and remove the connecting member,
The outer body and the padding can be separated from the spring unit.

[0013]

Embodiments of the present invention will be described below with reference to the drawings.

FIGS. 1 to 3 show a first embodiment of the present invention. The mattress device shown in FIG. The spring unit 1 is formed by arranging a large number of coil springs 2 in a matrix and connecting upper and lower end surfaces of adjacent coil springs 2 with a helical wire 3. A frame line 4 is connected to upper and lower peripheral edges of the spring unit 1 by clips (not shown).

On the upper and lower surfaces of the spring unit 1, paddings 6 each formed in a rectangular shape slightly larger than the upper and lower surfaces of the spring unit 1 are stacked and stacked via a sheet-like protective material 5 such as felt. Is placed. The filling 6 is formed by compressing synthetic fiber into a layer having a predetermined thickness.

The laminate of the spring unit 1 and the padding 6 is covered with an outer package 7. The exterior body 7 includes an upper mirror section 8 and a lower mirror section 9 which are respectively laminated on the upper and lower surfaces of the spring unit 1, and a gusset section 10 covering the outer peripheral surface. The mirror portions 8, 9 and the town portion 10 are respectively composed of outer materials 8a, 9a, 10a and linings 8b, 9
b, 10b between the sheet-like urethane foam 8c,
9c and 10c are provided, and the three members are integrally quilted. The upper and lower ends of the gusset 10 are integrally sewn to the periphery of the upper mirror 8 and the lower mirror 9 by a tape 11.

The linings 8b and 9b of the mirrors 8 and 9 have
One end in the width direction of the flange cloth 12 is sewn over the entire periphery of the peripheral portion, and the other end covers the outer peripheral surface of the padding 6 as shown in FIG. A relatively soft heat-shrinkable synthetic resin tape is formed in a loop shape on the frame line 4 at both ends in the height direction of the spring unit 1, which is the outer surface of the other end of the flange cloth 12. The connecting member 13 is held by utilizing the elasticity of the padding 6.

As the relatively soft heat-shrinkable resin forming the connecting member 13, vinyl chloride resin, EPT, P
ETP, cross-linked polyethylene, silicone rubber, and the like are used, and a phenomenon is attempted in which these resins are heat-molded, and the molded product is reheated to return to its original shape. Therefore, when the connecting member 13 is heated, the loop shape of the connecting member 13 contracts, so that the flange cloth 12
Is pressed and fixed to the outer peripheral surface of the spring unit 1 so as to wrap the peripheral portion of the padding 6.

When the other end of the flange cloth 12 is fixed to the spring unit 1, the mirrors 8, 9 to which the one end is connected are also fixed to the spring unit 1, and the padding 6 wrapped around the periphery. Are also fixed to the spring unit 1.

After the connecting member 13 is thermally shrunk, the upper and lower ends of the gusset 10 of the exterior body 7 are formed around the mirrors 8 and 9 by the tape 12 as described above. Sewn on.

FIGS. 3A to 3D show the steps of manufacturing the mattress device having the above-described structure. FIG. 3A shows a first step. In this first step, the padding 6 and the mirror parts 8 and 9 are stacked on the upper and lower surfaces of the spring unit 1 via the protective material 5. The other end of the flange cloth 12 having one end sewn to the periphery of the inner surface of each of the mirror portions 8 and 9 is in a state of covering the outer peripheral surface of the padding 6.

A padding 6 is provided on the upper and lower surfaces of the spring unit 1.
After the mirror portions 8 and 9 are laminated, a loop-shaped connecting member 13 is provided on the outer peripheral surface of the other end of the flange cloth 12 as a second step, as shown in FIG.

Next, as a third step shown in FIG. 3 (c), the laminate of the spring unit 1, the padding 6, and the mirror parts 8, 9 provided with the connecting member 13 is put into the hot air heating furnace 22 by the conveyor 21. It is carried in. The warm air in the heating furnace 22 is at a temperature of 50 to 130 ° C., which is a temperature at which the connecting member 13 can be heated and shrunk, and when the connecting member 13 is heated and shrunk together with the laminate at that temperature, a flange cloth 12 is pressed against the outer peripheral surface of the spring unit 1 and fixed. When the other end of the flange cloth 12 is fixed to the spring unit 1, the padding 6 and the mirror parts 8, 9 are also fixed to the spring unit 1.

In a fourth step shown in FIG. 3D, the spring unit 1 of the laminate unloaded from the heating furnace 22 is used.
Is covered with a gusset 10, and the upper and lower ends of the gusset 10 are sewn to the periphery of the upper mirror section 8 and the lower mirror section 9 with a tape 12, as shown in FIG. A mattress device will be manufactured.

According to the mattress device manufactured in this manner, the paddings 6 and the mirror portions 8 and 9 stacked on the upper and lower surfaces of the spring unit 1 are provided with one end portions connected to the mirror portions 8 and 9. It is fixed to the above-mentioned spring unit 1 through the other end of the flange cloth 12 provided. That is,
By fixing the flange cloth 12 to the outer peripheral surface of the spring unit 1 by thermally contracting the connecting member 13, the padding 6 and the exterior body 7 are fixed to the spring unit 1.

Therefore, the padding 6 and the mirror portions 8 and 9 stacked on the spring unit 1 do not need to be connected to the spring unit 1 by using many clips as in the related art, and the connecting member 13 is thermally contracted. Can be connected and fixed to the spring unit 1 alone, so that the operation of connecting and fixing the padding 6 and the mirror portions 8 and 9 to the spring unit 1 can be easily and quickly automated without manual work. It can be carried out.

On the other hand, when the spring unit 1 is separated from the padding 6 and the exterior body 7 in order to discard the mattress device having the above structure, the tape 11 in which the gusset 10 is connected to the mirrors 8 and 9 is used. After removing the gusset 10 from the outer peripheral surface of the spring unit 1, the connecting member 13 to which the outer peripheral surface of the spring unit 1 is fastened is cut along the width direction by, for example, a cutter. Thereby, if the connecting member 13 is removed from the outer peripheral surface of the spring unit 1, the fixed state of the other end of the flange cloth 12 can be released.

As a result, the padding 5 and the mirror parts 8, 9 can be separated from the spring unit 1. That is, at the time of disposal, the padding 6 and the outer package 7 can be separated from the spring unit 1 by a relatively easy operation of cutting the connecting member 13 formed of a tape-shaped synthetic resin.

FIG. 4 shows a second embodiment of the present invention. In this embodiment, the other end of the flange cloth 12 is formed longer than one end, and the other end can cover the winding portion 2a of the coil spring 2 located around the spring unit 1 at the other end. . The other end of the flange cloth 12 is held and fixed by the connecting member 13 at the winding portion 2a of the coil spring 2. Even in such a configuration, the first embodiment is used. The same operation and effect as described above can be obtained.

FIG. 5 shows a third embodiment of the present invention. In the third embodiment, the upper mirror 7 and the gusset 10 of the exterior body 7 are integrally formed. According to such a configuration, after the connecting member 13 is contracted, It is only necessary to sew the lower end portion of the lower mirror portion 9 and the peripheral portion of the lower mirror portion 9 with the tape 11.

In each of the above embodiments, if the other end of the flange cloth 12 and the connecting member 13 are partially adhered to each other with a hot-melt adhesive which cures at a temperature of about 50 ° C., for example, Since the member 13 is integrated with the flange cloth 12, the displacement of the connecting member 13 can be prevented.

In each of the above embodiments, a so-called double-sided mattress in which the upper and lower surfaces of the spring unit are provided with the padding and the mirror portion of the exterior body respectively has been described. However, the spring unit is fixedly provided on the substrate, and the padding is provided only on the upper surface thereof. The present invention can also be applied to a so-called bottom mattress in which a top surface and an outer peripheral surface are provided with an exterior body.

The flange cloth provided on the peripheral portion of the inner surface of the mirror portion may be provided continuously over the entire periphery of the peripheral portion, or may be provided partially. It does not matter. Further, the connecting member is not limited to a tape shape, but may be a tube shape.

[0034]

As described above, according to the present invention, one end of the flange cloth is connected to the inner peripheral part of the mirror part constituting the exterior body, and the other end of the flange cloth is connected to the entire outer peripheral surface of the spring unit. And a connecting member made of a heat-shrinkable synthetic resin provided over the spring unit, and the connecting member is contracted to be fixed to the spring unit.

Therefore, since the padding and the outer package are fixed to the spring unit via the flange cloth, it is not necessary to use a large number of clips as in the prior art, and the connection work is facilitated and speeded up. be able to. In addition, since the operation of thermally shrinking the connecting member can be easily automated, the productivity can be improved by this.

Further, when disposing the mattress device having the above-described structure in an area where sorting and collection are performed, the exterior member and the padding can be separated from the spring unit by cutting the connecting member made of synthetic resin. Therefore, it is possible to easily perform the operation of separating the components constituting the mattress device for each material.

[Brief description of the drawings]

FIG. 1 is a sectional view of a part of a mattress device according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of a state before the gusset of the exterior body is attached.

FIG. 3 is an explanatory view of a manufacturing process of the mattress device.

FIG. 4 is a cross-sectional view of a part of a mattress device according to a second embodiment of the present invention.

FIG. 5 is a cross-sectional view of a part of a mattress device according to a third embodiment of the present invention.

[Explanation of symbols]

1: spring unit, 6: filling, 7: exterior body, 8,
9: mirror part, 10: town part, 12: flange cloth, 13: connecting member.

Claims (2)

(57) [Claims] 1. A spring unit having an upper surface and a lower surface, a filling layer laminated on at least the upper surface of the spring unit, a mirror part covering at least an upper surface of a laminated body of the filling unit and the spring unit, and a town covering the outer peripheral surface. And a flange cloth, one end of which is connected to the inner peripheral part of the mirror part, and a flange cloth formed of a heat-shrinkable synthetic resin and extending over the entire outer peripheral surface of the spring unit. A mating device provided with a connecting member for holding the other end of the flange cloth and being heated and contracted to fix the flange cloth to the spring unit. 2. A method of manufacturing a mattress device comprising a laminate in which a padding is laminated on at least the upper and lower surfaces of an upper and lower surfaces of a spring unit with an exterior body having a mirror portion and a gusset portion. Laminating the padding on the upper surface, connecting one end of the flange cloth to the inner peripheral part of the mirror part, and holding the other end of the flange cloth over the entire outer peripheral surface of the spring unit and heat. A mattress comprising: a step of providing a connecting member made of a shrinkable synthetic resin; and a step of heating the connecting member to shrink it to fix the other end of the flange cloth to the spring unit. Manufacturing method for equipment.