JP2959924B2 - 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 moving by the clip, and the outer body is prevented from moving by the flange cloth. However, since the operation of connecting the padding to the spring unit with a large number of clips requires a great deal of time and labor, the productivity may be reduced.In addition, the operation of connecting the flange cloth by the spring unit may be required. It can take a lot of time.

On the other hand, when the mattress device is damaged due to long-term use and must be discarded, recently, the waste is not 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.

[0007]

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.

[0008] The present invention has been made based on the above circumstances, and an object of the present invention is to be able to connect a padding and an outer package to a spring unit without using a large number of clips, and to easily disassemble the package. And a method for manufacturing the same.

[0009]

According to the present invention, there is provided a mattress device comprising: a spring unit having an upper surface and a lower surface;
A padding laminated on at least the upper surface of the spring unit, an exterior body having a mirror portion covering at least the upper surface of the laminate of the padding and the spring unit, and a gusset covering the outer peripheral surface; and a heat-shrinkable fiber. And one end in the width direction is connected to the inner surface of the mirror portion and is heated and shrunk, and the other end is engaged with the outer peripheral edge of the spring unit. And a connecting member.

The 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. In the step of laminating the padding on at least the upper surface of the spring unit, and a step of connecting one end in the width direction of a connecting member made of a fabric formed of heat-shrinkable fibers around the inner surface of the mirror, A step of laminating the mirror portion to the padding so that the other end in the width direction of the connecting member covers the outer peripheral portion of the padding; and heating and contracting the connecting member so that the other end is outside the spring unit. Engaging with the peripheral portion.

[0011]

According to the above construction, the connecting member whose one end is connected to the mirror portion of the exterior body is contracted by heating, so that the other end can be engaged with the outer peripheral edge of the spring unit. The connecting work can be easily and quickly performed, and the padding and the outer body connected to the spring unit by the connecting member can be easily removed by simply cutting and removing the connecting member made of synthetic resin tape. Can be separated from the unit.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 3 show a first embodiment of the present invention. The mattress device shown in FIG.
Having. 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 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 town section 11 which covers the outer peripheral surface. These mirror parts 8 and 9 and the town part 11 are composed of outer materials 8a, 9a and 11a and linings 8b, 9b and 11b.
Between the sheet-like urethane forms 8c, 9c, 11
c, 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 8 and the lower mirror 9 by a tape 12.

On the linings 8b, 9b of the mirrors 8, 9,
One end 13a in the width direction of a tape-shaped connecting member 13 bent into an L-shaped cross section over the entire periphery is connected by means such as adhesion or sewing. This connecting member 13
Is made into a thread by twisting a relatively soft heat-shrinkable synthetic resin fiber, and the yarn is knitted or woven without being knitted, that is, in the form of a cloth.

As the heat-shrinkable resin forming the connecting member 13, vinyl chloride resin, EPT, PETP, cross-linked polyethylene, silicone rubber and the like are used. These resins are molded by heating and the molded product is reheated. Utilize the phenomenon of trying to return to the original form by doing.

In a state in which the mirror parts 8 and 9 are laminated on the protective member 5, one end 13a in the width direction of the connecting member 13 is connected to the upper surface of the peripheral part of the protective member 5 (spring unit 1) as shown in FIG. And the other end 13b covers the outer peripheral surface of the protective material 5.
When the connection member 13 is heated and contracted in this state,
Since the other end 13b covering the outer peripheral surface of the protection member 5 is bent inward, the other end 13b is engaged with the upper and lower peripheral edges of the spring unit 1 as shown in FIG.

After the connecting member 13 is thermally contracted, the upper and lower ends of the gusset 11 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 the first step, the padding 6 is laminated on the upper and lower surfaces of the spring unit 1 via the protective material 5. FIG. 3 (b)
Is a second step performed in parallel with the first step in time. In the second step, the lining 8 of the upper mirror section 8 and the lower mirror section 9
One end in the width direction of the connecting member 13 is bonded and fixed to the inner peripheral portions of b and 9b by an adhesive or sewing.

In the third step shown in FIG. 3C, the upper mirror 8 and the lower mirror 9 to which the connecting member 13 is fixed are stacked on the padding 6 stacked on the upper and lower surfaces of the spring unit 1. Is done.

The spring unit 1 on which the mirror portions 8 and 9 are stacked in the third step is carried into the hot air heating furnace 22 by the conveyor 21 in the fourth step shown in FIG. In the air heating furnace 22, the air is heated to 50 to 130 ° C. by warm air. Therefore, each connecting member 13 provided on the inner surface of each of the mirror parts 8 and 9 thermally contracts, and the other end 13 in the width direction thereof
a engages the upper and lower peripheral edges of the spring unit 1.
As a result, the mirrors 8, 9 to which the one end 13a of the connecting member 13 is connected and fixed are fixed to the spring unit 1, and are provided between the mirrors 8, 9 and the upper and lower surfaces of the spring unit 1. Each padding 6 is also fixed to the spring unit 1. That is, the laminate of the spring unit 1, the padding 6, and the mirror portions 8, 9 is integrally connected.

In the fifth step, the outer peripheral surface of the spring unit 1 of the laminate 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 8 And tape 1 around the lower mirror 9
2, the mattress device shown in FIG. 1 is manufactured.

According to the mattress device manufactured as described above, the paddings 6 and the mirror portions 8 and 9 stacked on the upper and lower surfaces of the spring unit 1 are connected to the connecting members 13 provided on the mirror portions 8 and 9. It is connected to the spring unit 1 by heat-shrinking and engaging the other end 13b with the upper and lower peripheral edges of the spring unit 1.

That is, the padding 6 and the mirror parts 8 and 9 stacked on the spring unit 1 are not connected to the spring unit 1 by using many clips as in the prior art, and only the connection member 13 is thermally contracted. It can be connected and fixed to the spring unit 1. Therefore, the work of connecting and fixing the filling 6 and the mirror parts 8 and 9 to the spring unit 1 can be performed easily and quickly, and without manual work.
Can be automated.

Since the connecting member 13 is formed of heat-shrinkable synthetic resin fibers in a cloth shape, the connecting member 13 is superior in strength as compared with a case where it is formed of a sheet-shaped synthetic resin. for that reason,
In the assembling process, even if the connecting member 13 is scratched, the connecting member 13 is easily broken from the scratched portion as in the case where the connecting member 13 is formed from a synthetic resin sheet. There is no.

On the other hand, when separating the spring unit 1 from the padding 6 and the exterior body 7 in order to dispose of the mattress device having the above-described structure, the tape 12 having the gusset 11 connected to the mirrors 8 and 9 should be used. After removing the gusset 11 and removing the gusset 11, a cut is made in the other end portion 13b of the connecting member 13 engaged with the spring unit 1 along the width direction with a cutter or the like, for example. If the other end 13b is torn in the circumferential direction of the spring unit 1, the engagement between the connecting member 13 and the spring unit 1 can be released.

Thus, the padding 5 and the mirror parts 8 and 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 tearing 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 protective members 5
The padding 6 laminated via the above is partially adhered together with the protective material 5 by the hot melt 31. The hot melt 31 is a material that cures at a temperature lower than the temperature at which the connecting member 13 contracts, for example, about 50 ° C.

As described above, the filling 6 is transferred to the hot melt 31.
In this case, the hot melt 31 is cured and the filling 6 is fixed to the spring unit 1 before the connecting member 13 thermally contracts. Therefore, the connecting member 1
Even if the heat shrinkage of 3 does not progress uniformly in the circumferential direction of the spring unit 1, the padding 6 is prevented from shifting on the spring unit 1. Moreover, since the filling and fixing of the filling 6 by the hot melt 31 is partial,
At the time of disassembly, the filler 6 can be easily separated from the spring unit 1.

FIG. 5 shows a third embodiment of the present invention. In this embodiment, the thread member 32 is passed through the padding 6 laminated on the upper and lower surfaces of the spring unit 1, and buttons 33 are attached to both ends of the thread member 32, whereby the padding 6 is fixed to the spring unit 1.

According to such a configuration, since the padding 6 can be fixed to the spring unit 1 in advance, the spring member 1, the padding 6, and the laminated body of the mirror portions 8, 9 before the connecting member 13 is contracted. Is easy to handle.

FIG. 6 shows a fourth embodiment of the present invention. In this embodiment, the paddings 6 stacked on the upper and lower surfaces of the spring unit 1 are formed to have substantially the same size as the upper and lower surfaces of the spring unit 1.

As a result, when the connecting member 13 is contracted, the other end in the width direction may be more easily engaged with the upper and lower peripheral edges of the spring unit 1. FIG. 7 shows a fifth embodiment of the present invention. In this embodiment, the upper mirror section 8 of the exterior body 7 and the town section 11 are integrally formed. Therefore, when manufacturing such a mattress device, after the connecting member 13 is contracted by the hot air heating furnace 22, only the lower end portion of the gusset portion 11 and the peripheral portion of the lower mirror portion 9 are taped by the tape 12. Just suturing.

In the fifth embodiment, the outer package 7
The gusset 11 may be formed integrally with the lower mirror 9. In each of the above embodiments, the so-called double-sided mattress is described in which the upper and lower surfaces of the spring unit are respectively provided with the mirror portions of the padding and the exterior body.
The present invention is also applied to a so-called bottom mattress in which a spring unit is fixedly provided on a substrate, a padding is provided only on the upper surface, and the upper surface and the outer peripheral surface are covered with an exterior body having a mirror portion and a gusset portion. Can be. Further, the mirror part and the town part of the exterior body may be either integral or separate.

The connecting member may be provided continuously over the entire length of the peripheral portion of the inner surface of the mirror portion, but may be provided partially, and the point is not limited. Further, in order to thermally shrink the connecting member, the laminated body of the spring unit, the padding and the exterior body is placed in a hot-air heating furnace to heat the whole, but only the connecting member is heated, for example, from a nozzle. You may make it heat and contract by wind.

[0036]

As described above, according to the present invention, one end in the width direction of a connecting member formed of a cloth made of a heat-shrinkable synthetic resin fiber is connected to a peripheral portion of an inner surface of a mirror portion constituting an exterior body. By thermally shrinking the connecting member and engaging the other end with the spring unit, the padding layered on the spring unit and the exterior body forming a part of the mirror portion are fixed to the spring unit. I made it.

As a result, the padding and the outer casing can be connected and fixed to the spring unit without using a large number of clips as in the prior art, so that the connecting operation can be performed easily and quickly. 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 exterior body and the padding can be separated from the spring unit by cutting the connecting member made of synthetic resin. The operation of separating the components constituting the mattress device for each material can be easily performed.

[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 outer body is attached to the town.

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 fourth embodiment of the present invention.

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

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

[Explanation of symbols]

1: spring unit, 6: filling, 7: exterior body, 8,
9: mirror part, 11: town part, 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. Part, and one end in the width direction, which is formed of a cloth made of heat-shrinkable fiber, is connected to the inner surface of the mirror part and is provided along the outer peripheral part of the padding, and is shrunk by heating. And a connecting member having the other end engaged with 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 in the width direction of a connecting member made of a fabric formed of heat-shrinkable fibers to the periphery of the inner surface of the mirror, Laminating the mirror portion to the filling so that the end covers the outer periphery of the filling, and engaging the other end with the outer periphery of the spring unit by heating and contracting the connecting member. A method of manufacturing a mattress device, comprising: