JP2802880B2 - 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.

However, the operation of connecting and fixing 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 may be attached to the spring unit. The work of linking can also take a lot of time.

On the other hand, when a mattress device is damaged due to long-term use and must be discarded, recently, waste is collected only if the material is classified and discarded. In many areas, the system is adopted. When discarding a mattress device in an area where sorting and collection are being performed, the spring unit, which is a metal part, and a padding and an outer package made of synthetic cotton or the like must be discarded separately.

[0007] In this case, if the padding is connected to the spring unit by a 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 outer body is also connected to the spring unit via the flange cloth with the clip. In some cases, the assembling work takes a lot of time, and when it is necessary to disassemble each material at the time of disposal, the disassembling work takes time.

The present invention has been made in view of the above circumstances, and has as its object the purpose of being able to hold and fix a padding and an exterior body to a spring unit without using a large number of clips, and to easily disassemble the same. 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;
A heat-shrinkable fiber, comprising: an outer package having a filling layer stacked on the upper surface and the lower surface of the spring unit; an upper and lower mirror portion covering the upper and lower surfaces of a laminate of the filling member and the spring unit; The upper and lower mirrors are formed by woven or non-woven fabrics, and both ends are respectively connected to the inner peripheral portions of the upper and lower mirror portions, and are provided in the circumferential direction on the outer peripheral surface of the spring unit. And a connecting member for pulling the parts toward each other.

[0011] The method of manufacturing a mattress device according to the present invention is an exterior body comprising a laminated body in which a filler is laminated on the upper and lower surfaces of a spring unit, and an upper and lower mirror portion covering the filler and a town covering the outer peripheral surface of the spring unit. In a method of manufacturing a coated mattress device, a step of laminating the padding on the upper and lower surfaces of the spring unit, and forming a heat-shrinkable fiber around three inner surfaces except one side of the upper and lower mirror portions. A step of connecting both ends of a connecting member made of a woven or nonwoven fabric, and a step of inserting and placing the laminate between inner surfaces of the upper and lower mirror sections,
A step of connecting the connecting member to the one side of the upper and lower mirrors, and a step of contracting the connecting member by heating the connecting members and pulling the upper and lower mirrors in directions approaching each other. Features.

[0012]

According to the above construction, when assembling, the connecting members, both ends of which are connected to the inner surface peripheral portions of the upper and lower mirror portions, are contracted by heating, so that the upper and lower mirror portions are pulled in a direction approaching each other. The padding and the outer package can be fixed to the spring unit via the mirror portion. At the time of disassembly, the outer package and the padding can be separated from the spring unit only by cutting and removing the connecting member.

[0013]

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

FIGS. 1 to 5 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. To form a laminate 7. As the filling 6, for example, a synthetic fiber, urethane foam or the like formed to a predetermined thickness is used.

The laminate 7 of the spring unit 1 and the padding 6 is covered with an exterior body 8. The exterior body 8 includes an upper mirror portion 9 and a lower mirror portion 10 which are respectively laminated on the upper and lower surfaces of the spring unit 1, and a gusset portion 11 covering the outer peripheral surface. These mirror parts 9, 10 and town part 1
1 is the outer material 9a, 10a, 11a and the lining 9 respectively.
b, 10b, 11b, and sheet-like urethane foam
And 9c, 10c, and 11c, and the three are integrally quilted. The upper and lower ends of the gusset 11 are integrally sewn to the periphery of the upper mirror 9 and the lower mirror 10 by a tape 12.

As shown in FIG. 3, the linings 9b and 10b of the upper and lower mirror portions 9 and 10 are arranged at predetermined intervals in the circumferential direction. On both sides, three end portions of a first connection member 13 formed by forming a woven or non-woven fabric formed of heat-shrinkable fibers to an appropriate size are connected by sewing or bonding. . The height of the first connecting member 13 is set larger than the height of the laminate 7. As shown in FIG. 3 and FIG. 4, a woven or non-woven fabric made of heat-shrinkable fiber is formed in an appropriate size on the linings 9b and 10b at the four corners of the upper and lower mirror portions 9 and 10. One end of the second connecting member 14 is connected to the upper mirror 9
The other end of the second connecting member 14 connected to the spring unit 1 is bent to a lower peripheral edge on the upper side of the spring unit 1 and temporarily fixed to the spring unit 1 by bonding or the like. Similarly, the other end of the second connecting member 14 connected to the lower mirror section 10 is provided to bend at the lower peripheral edge of the lower side of the spring unit 1.

The first and second connecting members 13 and 14 are
It consists of a woven or non-woven fabric formed by heat-shrinkable fibers. Such heat-shrinkable fibers include vinyl chloride.
A resin formed by forming a fibrous resin, EPT, cross-linked polyethylene resin, or the like is used. A phenomenon in which these fiber molded products are heated and then reheated to return to the original shape is used.

Therefore, when the first connecting member 13 is heated, the first connecting member 13 contracts greatly in the vertical direction of the spring unit 1. It is pulled up and down, that is, in a direction approaching each other. Thereby, the periphery of the padding 6 is wrapped by the first connecting member 13, and the upper and lower surfaces are pressed onto the spring unit 1 by the mirror parts 9 and 10 and held and fixed to the spring unit 1. At the same time, the upper and lower mirror parts 9 and 10 are also pulled in a direction approaching each other, thereby tightening the laminate 7 together with the first connecting member 13 and being fixed to the spring unit 1. When the second connecting member 14 is heated at the same time, the second connecting member 1
4 also undergoes thermal contraction, and the other end engages the upper and lower peripheral edges of the spring unit 1. Although the upper and lower mirror parts 9 and 10 of the second connecting member 14 play a role of preventing rotation on the spring unit 1, the second connecting member 14 is not always required.

The gusset 11 of the exterior body 8 is formed by thermally shrinking the first and second connecting members 13 and 14.
The upper and lower ends are sewn to the periphery of the upper and lower mirror parts 9 and 10 by the tape 12 as described above.

FIGS. 5A to 5D show the steps of manufacturing the mattress device having the above-mentioned structure. FIG. 5A shows a first step. In the first step, the padding 6 is laminated on the upper and lower surfaces of the spring unit 1 via the protective material 5 to form a laminate 7. In the second step shown in FIG.
At predetermined intervals around the four inner surfaces of the upper and lower mirror portions 9 and 10
Is provided by connecting both ends thereof by sewing or bonding. At this time, the upper and lower mirror parts 9, 10
The lower end of the first connecting member 13 connected to one side in the longitudinal direction is not connected to the lower mirror 10 and is a free end. This is because the laminated body 7 is inserted and placed between the inner surfaces of the upper and lower mirror parts 9 and 10. Further, the first connecting member 1
3 is connected to the upper and lower mirror parts 9 and 10, and at the same time, one end of the second connecting member 14 is connected to the peripheral parts on the inner surfaces of the four corners of the upper and lower mirror parts 9.

In a third step shown in FIG. 5C, the laminate 7 is inserted and placed between the inner surfaces of the upper and lower mirror parts 9, 10 connected by the first connecting member 13. That is, the free end side of the first connecting member 13 which is not connected to the lower mirror portion 10 on one side in the longitudinal direction is lifted, and the stacked body 7 including the spring unit 1, the protective material 5 and the padding 6 is taken from that direction. Is inserted and placed between the inner surfaces of the upper and lower mirror portions 9 and 10. After that, the free end side of the one side first connecting member 13 not connected to the lower mirror unit 10 is connected to the lining 10b of the lower mirror unit 10 by bonding or the like. Since the height of the first connecting member 13 is larger than the height of the laminate 7, the laminate 7 can be easily inserted. Further, the other end of the second connecting member 14 whose one end is connected to the four corners of the upper mirror portion 9 is bent to the upper lower peripheral edge of the spring unit 1 and is temporarily fixed to the spring unit 1 by bonding or the like. Then, the other end of the second connecting member 14, one end of which is connected to the four corners of the lower mirror 10, is bent to the lower peripheral edge of the lower side of the spring unit 1.

As described above, if the laminate 7 in which the padding 6 is laminated on the upper and lower surfaces of the spring unit 1 is inserted and placed between the inner surfaces of the upper and lower mirror parts 9, 10, a fourth step shown in FIG.
As shown in (d), the laminate 7 and the upper and lower mirror parts 9, 10
Is transported into the hot air heating furnace 22 by the conveyor 21.

The temperature in the heating furnace 22 depends on the first and second temperatures.
50 to 130 ° C., which is a temperature at which the connecting members 13 and 14 can be heated and shrunk, at which temperature the first connecting member 13 is heated together with the laminated body and in the height direction of the spring unit 1. When contracted, the upper and lower mirror parts 9, 1
Zeros are pulled in directions approaching each other. When the upper and lower mirrors 9 and 10 are pulled in a direction in which they approach each other, the upper and lower mirrors 9 and 10 press the padding 6 onto the spring unit 1 and the first connecting member 13.
Thereby, a part of the peripheral portion is wrapped and held and fixed to the spring unit 1. At the same time, the upper and lower mirror parts 9 and 10 are also fixed to the spring unit 1. Further, at the same time when the first connection member 13 is heated, the second connection member 1 is heated.
4 is also heated. When the second connecting member 14 is heated, it contracts and engages with the lower peripheral edge of the spring unit 1. As a result, the upper and lower mirror portions 9 and 10 are
It acts as a detent on the top. However, the second connecting member 14 fixes the upper and lower mirror portions 9 and 10 to the spring unit 1 more securely, but is not always necessary.

In a fifth step, the outer peripheral surface of the spring unit 1 of the stacked body carried out of the heating furnace 22 is covered with the gusset 11, and the upper and lower ends of the gusset 11 are covered with the upper mirror 9 Then, the mattress device shown in FIG. 1 is manufactured by suturing the peripheral portion of the lower mirror portion 10 with the tape 12.

According to the mattress device manufactured as described above, the paddings 6 and the upper and lower mirror portions 9 and 10 laminated on the upper and lower surfaces of the spring unit 1 are combined with the upper and lower mirror portions 9 and
A first connecting member 13 having both ends connected to the first connecting member 13
The upper and lower mirror portions 9 and 10 are fixed in the spring unit 1 by being contracted by heat in a direction in which the upper and lower mirror portions 9 and 10 approach each other. That is, the first connecting member 13 is thermally contracted and the mirror parts 9 and 10 are pulled in a direction approaching each other, so that the padding 6 and the exterior body 8 are fixed to the spring unit 1.

Therefore, the padding 6 and the upper and lower mirror parts 9 and 10 stacked on the spring unit 1 do not need to be connected to the spring unit 1 by using many clips as in the prior art. Can be connected and fixed to the spring unit 1 only by heat shrinking, the operation of connecting and fixing the padding 6 and the upper and lower mirror parts 9 and 10 to the spring unit 1 can be performed easily and quickly.
Moreover, it can be performed automatically without manual operation.

On the other hand, when the spring unit 1 is separated from the padding 6 and the exterior body 8 in order to discard the mattress device having the above-described structure, the tape 12 having the gusset 11 connected to the mirrors 9 and 10 should be used. After removing the gusset 11 from the outer peripheral surface of the spring unit 1 or cutting the middle of the gusset 11 in the height direction with a cutter or the like along the circumferential direction, the outer periphery of the spring unit 1 is removed. The first connecting member 13 and the second
Is cut with a cutter or scissors. As a result, the upper and lower mirror portions 9 and 10 are not pulled by the first connecting member 13 in a direction approaching each other.

When the upper and lower mirror portions 9 and 10 are not pulled in the direction in which they approach each other, the holding and fixing state of the padding 6 and the upper and lower mirror portions 9 and 10 is released. The padding 6 and the upper and lower mirror parts 9 and 10 can be separated. That is, at the time of disposal, the spring unit is cut by the relatively easy operation of cutting the first connecting member 13 made of a woven or non-woven fabric of heat-shrinkable fibers partially provided on the outer periphery of the spring unit 1. The padding 6 and the exterior body 8 can be separated from 1.

FIG. 6 shows a second embodiment of the present invention. In this embodiment, the protective material 5 and the padding 6 laminated on the upper and lower surfaces of the spring unit 1 are partially, that is, bonded to the extent that they can be easily separated by a hot melt 31 as an adhesive.

According to such a configuration, at the time of assembling, before the first connecting member 13 is thermally contracted,
Since the protective member 5 and the padding 6 laminated on the spring unit 1 can be prevented from shifting, the assembling accuracy can be improved.

FIG. 7 shows a third embodiment of the present invention. In this embodiment, the thread-like member 32 is used to fix the protective material 5 and the padding 6 laminated on the upper and lower surfaces of the spring unit 1 to the spring unit 1. That is, the spring unit 1, the protective material 5 and the padding 6
The protective member 5 and the stuffing 6 are connected to the spring unit 1 by passing the thread-like member 32 through the laminate 7 and connecting the buttons 33 to both ends of the stuffing 6 respectively.
It is intended to be fixed to.

FIG. 8 shows a fourth embodiment of the present invention. In the fourth embodiment, the upper mirror portion 9 and the gusset portion 11 of the exterior body 8 are integrally formed. In the case of manufacturing a mattress device having such a configuration, the first connecting member 13 is required. After contraction, the lower end of the gusset 11 and the periphery of the lower mirror 10 need only be sewn together with a tape 12.

Note that a first portion provided around the inner surface of the mirror portion is provided.
Although the connecting member is provided partially on the periphery thereof, it may be provided over the entire circumference, and may have any configuration.

[0035]

As described above, according to the present invention, a connecting member made of a woven or non-woven fabric formed of heat-shrinkable fibers is provided around the inner surfaces of the upper mirror portion and the lower mirror portion constituting the exterior body. The two end portions are connected to each other and provided in the circumferential direction of the spring unit, and the connecting member is heated and contracted to pull the upper and lower mirror portions in a direction approaching each other,
The padding and the outer package are fixed to the spring unit.

Therefore, the padding and the outer casing are fixed to the spring unit by the contraction of the connecting member.
It is not necessary to use a large number of clips as in the related art, and the connection work can be facilitated and speeded up. 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 structure in an area where sorting and collection are performed, the outer member and the padding can be separated from the spring unit by cutting the connecting member of the woven or nonwoven fabric. Therefore, it is possible to easily perform the work 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 an explanatory view showing a state in which a laminate is inserted and mounted on an exterior body before heating.

FIG. 3 is an explanatory diagram showing connection positions of first and second connection members in the mirror unit.

FIG. 4 is a cross-sectional view of a corner portion of the mattress device showing an engagement state of the second connecting member.

FIG. 5 is an explanatory view of a manufacturing process of the mattress device.

FIG. 6 is a cross-sectional view of a part of a mattress device according to a second embodiment of the present invention.

FIG. 7 is a cross-sectional view of a part of a mattress device according to a third embodiment of the present invention.

FIG. 8 is a cross-sectional view of a part of a mattress device according to a fourth embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Spring unit 6 Stuffing 7 Laminated body 8 Exterior body 9 Upper mirror part 10 Lower mirror part 11 Town part 13 1st connection member

Claims (2)

(57) [Claims] 1. A spring unit having an upper surface and a lower surface, a padding stacked on the upper surface and a lower surface of the spring unit, an upper and lower mirror unit and an outer peripheral surface which cover upper and lower surfaces of a stacked body of the padding and the spring unit. An outer body having a covering portion, and a woven or non-woven fabric formed of heat-shrinkable fibers, both ends of which are connected to the inner peripheral portions of the upper and lower mirror portions, respectively, in a circumferential direction on the outer peripheral surface of the spring unit. A mating device, comprising: a connecting member provided on the upper surface of the upper and lower portions, the upper and lower mirror portions being pulled by heating and contracting in a direction approaching each other. 2. A mattress device comprising: a laminate in which a filler is laminated on upper and lower surfaces of a spring unit; and an outer body comprising a mirror portion covering the filler and a gusset covering an outer peripheral surface of the spring unit. In the method, the step of laminating the padding on the upper and lower surfaces of the spring unit, and on the inner peripheral portion on three sides except one side of the upper and lower mirror portions,
A step of connecting both ends of a connecting member made of a woven or nonwoven fabric formed of heat-shrinkable fibers, a step of inserting and placing the laminate between inner surfaces of the upper and lower mirror sections, and A mating device, comprising: a step of connecting a connecting member to the one side; and a step of contracting the connecting member by heating the connecting member to pull the upper and lower mirror portions in a direction approaching each other. Manufacturing method.