JP6827745B2 - Compression packing method for multi-fold cushion body - Google Patents

Description

The present invention relates to a method of compressing and packing a cushion body made of a synthetic resin foam, and in particular, a cushion body with a cover that can be folded in a plurality of pieces (hereinafter, may be referred to as a “multi-fold cushion body”). Even if there is, it relates to a compression packing method that can perform compression and winding smoothly.

Cushion bodies made of synthetic resin foam used for bedding such as mattresses, mattresses, and mattresses may have problems in storage space and transportation due to their bulky structure.
The applicant of the present application has abbreviated by first winding the porous strip-shaped elastic sheet (1) around the winding shaft (3) while sandwiching and compressing it between the winding shaft (3) and the rigid body (4). We are proposing a method for improving handleability by forming a columnar body so that it can be stored and transported in a limited place (see Patent Document 1).

Further, in recent years, a compression winding device 10 as shown in FIG. 1 has been widely used when packing a cushion body made of a synthetic resin foam.
FIG. 1 is a diagram for schematically explaining an example of a conventionally known compression winding device 10, wherein the device 10 has at least a transport belt 60 and at least one pair (one pair in the drawing) of compression rolls 40. , 40, a plurality of (8 in the figure) feed rolls 50, 50, ... 50 arranged at intervals along the generatrix direction so as to form the outer peripheral surface of the roughly cylindrical body 501. Have.

Conventionally, in such a compression winding device 10,
First, the multi-fold cushion body 2 is placed on the transport belt 60, compressed between the compression rolls 40, 40, and then.
It is inserted into the internal space s of the substantially cylindrical body 501 composed of the feed rolls 50, 50, ... 50 while being compressed, and there, the rotation of each feed roll 50 in the direction of the arrow (counterclockwise in the figure). As a result, it is wound in the opposite direction to the rotation and wound in a spiral shape.
Usually, before the spiral body is loosened, it is packed in a bag (not shown), or the spiral body is held by using a band or the like.

However, in the device 10 as described above, when a plurality of cushioning materials are used for a multi-fold cushion body housed in a cover having a connecting portion, the connecting portion of the cover pulls the transport roll in the path during compression extrusion. There was a concern that it would be unbearable and damaged.

Special Publication No. 46-10306

In consideration of the above points, the present invention compresses and compresses and extrudes a multi-fold cushion body in the path without damaging the connecting portion of the cover because it cannot withstand the tension of the transport roll. An object of the present invention is to provide a compression packing method for a multi-fold cushion body capable of smooth winding.

According to the present invention, the cushion body is housed in each bag-shaped member of a cover composed of a plurality of bag-shaped members and a connecting portion, and the multi-fold cushion body is configured so that the cushion body can be folded at the connecting portion. After compressing with at least a part of one side or both sides covered with a sheet made of non-woven fabric, woven cloth or knitted cloth, the compressed body is composed of a plurality of feed rolls arranged at intervals in the bus direction. It is transferred to the internal space of the roughly cylindrical body, wound in a spiral shape by being wound by the rotation of the plurality of feed rolls, and then, in the spiral shape, at one open end of the internal space. A compression packing method for a multi-fold cushion body to be packed in a bag set at the outer end of an installed tubular member, wherein the sheet is made of synthetic fiber, semi-synthetic fiber or natural fiber monofilament or multifilament. Moreover, the amount of the texture is 8 to 30 g / m ² .
Further, the multi-fold cushion body may be compressed in a state where one side is covered with a sheet and the sheet is folded in half so that the sheet is on the outside.
In addition, the seat may be installed so as to straddle at least a part of the adjacent cushion bodies.

In the compression packing method of the present invention, one side or both sides of the multi-fold cushion body is covered with a specific sheet before the multi-fold cushion body is compressed, so that the slipperiness of the multi-fold cushion body is improved and compression is extruded. At that time, the connecting portion of the cover does not endure the tension of the feed roll and is not damaged, and the compression and winding can be smoothly performed.

It is a figure schematically explaining an example of the conventionally known compression winding apparatus. (A) is a schematic perspective view of the multi-fold cushion body, and (B) is a cross-sectional view taken along the line AA of (A). It is a schematic perspective view explaining an example which covers both sides of the multi-fold cushion body with a sheet in the method of this invention. (A) to (C) are schematic perspective views for explaining another example of covering one side or both sides of a multi-fold cushion body with a sheet. It is the schematic perspective view explaining the example which covers a part of the adjacent cushion bodies. It is a schematic perspective view explaining an example of the substantially cylindrical body after compression and winding in the method of this invention. It is a figure for demonstrating an example of the structure of a feed roll. It is a figure explaining an example of the state of the bag set in the outer end portion of the tubular member in the method of this invention.

The compression packing method of the present invention
i) As shown in FIG. 2, the cushion materials 211, 212, and 213 made of synthetic resin foam are housed in a cover 20 formed by connecting a plurality of bag-shaped storage members 201. The connecting portion 202 is configured to be foldable, and as shown in FIGS. 3 to 5, one or both sides of the multi-fold cushion body 2 is a non-woven fabric, woven cloth, or knitted cloth sheet (hereinafter, also simply referred to as “sheet”). After compressing while covering with)
ii) This compressed body is transferred to the internal space of a substantially cylindrical body formed by arranging a plurality of feed rolls at intervals in the generatrix direction, and is wound by rotation of the plurality of feed rolls. This winds up in a spiral as shown in FIG. 6, and then
iii) As shown in FIG. 8, the spiral shape is packed in a bag set at the outer end of the tubular member installed at one open end of the internal space.
The compression of i) and the winding of ii) may be performed using, for example, a conventionally known compression winding device 10 as illustrated in FIG. 1, but in the present invention, for example, FIG. As shown in 4, one side or both sides of the multi-fold cushion body 2 is covered with a specific sheet 3 as described later, and then compressed.

FIG. 3 is a schematic perspective view illustrating an example in which both sides of the multi-fold cushion body 2 as shown in FIG. 2 are covered with two sheets 3 and 3 in the method of the present invention.
In the figure, reference numeral x indicates the width of the multi-fold cushion body 2, reference numeral y indicates the same length, and reference numeral z indicates the same height (thickness).

i) Compression The method of the present invention is different from the above-mentioned conventional method, that is, the method in which the cushion body 2 is placed as it is on the transport belt 60 in FIG. 1, for example, a multi-fold cushion as shown in FIG. While one side or both sides (both sides in FIG. 3) of the body 2 are covered with the sheet 3, the body 2 is placed on the transport belt 60 and compressed by one or a plurality of pairs of compression rolls 40 and 40.

In the present invention, as shown in FIG. 4A, the multi-fold cushion body 2 whose one side is covered with one sheet 3 is folded in half together with the sheet 3 along the length y direction, and then the transfer is performed. It can also be placed on the belt 60. Further, although not shown in FIG. 4, the multi-fold cushion body 2 whose one side is covered with one sheet 3 may be folded in half together with the sheet 3 along the width x direction.
In the example of FIG. 4A, the multi-fold cushion body 2 is placed on one sheet 3, and the multi-fold cushion body 2 is folded in half together with the sheet 3 at the center position in the length y direction. Although another example of a state in which both sides of the multi-fold cushion body 2 are covered with the sheet 3, one side (see FIG. 4 (B)) or both sides (see FIG. 4 (C)) of the multi-fold cushion body 2 folded in half is shown. )) Covered with the sheet 3 may be placed on the transport belt 60.
Further, in the present invention, depending on the physical properties of the cushion body, the plurality of folded cushion bodies 2 may be folded in three or three outside, and one or both sides thereof may be covered with one or two sheets.

As shown in FIG. 5, the present invention may have a configuration in which tape-shaped sheets 3 and 3 are wound around the outer periphery of the cushion material so as to straddle the adjacent cushion materials 211 and 212, 212 and 213.
In order to exert the effect of the present invention, it is necessary to cover 10% or more of the surface areas of the cushion materials 211, 212 and 213 with the sheet 3.
If the opening 203 of the cover 20 has a fastener (not shown), the cover 20 may get caught in the fastener and be damaged in the process of compression / winding. Damage can be prevented by covering with 3.

ii) Winding Next, the multi-fold cushion body 2 compressed while covering one or both sides with the sheet 3 is inserted into the internal space s of the substantially cylindrical body 501 as shown in FIG. 1, and a plurality of feeds are fed. By rotating the rolls 50, 50, ... 50, the rolls 50, 50, ... 50 are rotated in the direction opposite to the rotation, and are wound in a spiral shape as shown in FIG. Hereinafter, the mode in which the sheet 3 is wound in a spiral shape may be referred to as a “substantially cylindrical body 7”.
Although not shown in FIG. 1, a multi-fold cushion body is provided by providing at least one claw-shaped protrusion 81 as shown in FIG. 7 on the surface of each feed roll 50 (two in FIG. 7). The followability and winding property of 2 may be improved.

As described above, in the present invention, when the multi-fold cushion body 2 is compressed and extruded with the sheet 3 covering one side or both sides, the sheet 3 improves the slipperiness, and the connecting portion 202 has an excessive tensile force. Can be satisfactorily wound in the internal space s of the substantially cylindrical body 501 without damaging the connecting portion 202.

FIG. 6 is a schematic perspective view illustrating an example of the substantially cylindrical body 7 after i) compression and ii) winding in the method of the present invention, in which reference numeral d is the diameter of the substantially cylindrical body 7. The reference numeral h indicates the same height.
The height h is usually substantially equal to the width x of the cushion body 2, but for example, when it is folded in half and then compressed as shown in FIGS. 4 (A) to 4 (C), it is about x / 2. Become.

iii) Packing In the present invention, the bag is packed in a spiral shape as shown in FIG. 6 (not shown in FIG. 6). The mouth of the bag after packing is preferably sealed with a heat laminate or the like from the viewpoint of preventing loosening of the spiral body and hygiene.
Although not shown in FIG. 1, the compression winding device 10 includes a piston member for extruding the substantially cylindrical body 7 after winding from the internal space s, and the substantially cylindrical body 7 extruded by the piston member. It has a tubular member (a member drawn by a dotted line with reference numeral 51 in FIG. 8) for receiving the receiver. In FIG. 8, the packing bag 71 is set by inserting the opening of the bag 71 into the outer end of the tubular member 51.
By changing the diameters of the tubular member 51 and the bag 71, the diameter d of the spiral substantially cylindrical body 7 can be further compressed.

<Sheet>
The sheet 3 as described above is a non-woven fabric, a woven fabric, or a knitted fabric, which is made of a monofilament or a multifilament of synthetic fibers and has a basis weight of 8 to 30 g / m ² .
If the basis weight is too small, the strength will be insufficient and the sheet may be torn together with the cover during winding. Even if the sheet is torn, there is no problem as long as the cover material is not damaged. Further, if the basis weight is too large, the stiffness (shape memory of the non-woven fabric itself) is strong, the packing workability is lowered, and the multi-fold cushion body 2 cannot be covered well, and the weight is reduced during transportation and the cost is reduced. It is also not preferable from the viewpoint.

Examples of the monofilament (structure composed of single fibers) or multifilament (structure in which dozens of single fibers are twisted) of synthetic fibers include polyester, polyolefin, nylon, and polyurethane. When natural fibers such as cotton, recycled fibers such as rayon and cupra, and semi-synthetic fibers such as acetate are used, the strength is low and the cover may be damaged during winding.

In particular, a non-woven fabric is suitable because it has less fraying during cutting than a woven fabric or a knitted fabric, and its strength does not decrease depending on the pulling direction.
The tensile strength of the non-woven fabric according to JIS L1913 is 30 N / 5 cm or more for vertical (MD) and 10 N / 5 cm or more for horizontal (CD), and the elongation rate is 25% or more for vertical (MD) and horizontal (CD). ) Is in each range of 20% or more, it becomes difficult to tear during winding, which is preferable.

When the sheet 3 is made of, for example, a synthetic resin film instead of a non-woven fabric, a woven fabric, or a knitted fabric, the frictional resistance with the multi-fold cushion body is too low in the winding step, and only the film rotates the feed roll. Depending on the material of the film, the strength is low and the film may be torn during winding.

Further, as shown in FIGS. 3 and 4, when two sheets 3 and 3 are used, each sheet 3 may be the same or different in terms of composition, material, physical properties and the like.

<Multi-fold cushion body>
As shown in FIGS. 2A and 2B, the multi-fold cushion body 2 is a cover formed by connecting a plurality of bag-shaped storage members 201, 201, 201 via connecting portions 202, 202. Cushion materials 211, 212, and 213 made of synthetic resin foam are housed in 20, and the connecting portion 202 is configured to be foldable.
In the covers shown in FIGS. 2A and 2B, the upper ends or the lower ends of the adjacent bag-shaped storage members are connected by the connecting portion 202, but the present invention is not limited to this, and the upper ends, the lower ends, and the side ends are not limited to each other. Various connection methods can be adopted.
2 (A) and 2 (B) show tri-folding, but the present invention is not limited to this, and may be double-folded or quadruple-folded or more. The cover 20 may be provided with an opening 203 so that the cushion body can be attached and detached.
As the material of the cover 20, polyethylene, polypropylene, polyester, hemp, nylon, polyvinyl chloride, rayon, silk, cotton, cupra and the like can be used. The basis weight of the cover is preferably 120 to 190 g / m ² .
The material and size of the cushion material are not particularly limited as long as they are made of synthetic resin foam used for bedding such as mattresses, mattresses, and mattresses. Examples of the material include flexible polyurethane foam and flexible polyethylene foam.

<Bag>
The bag 71 as shown in FIG. 8 for packing the substantially cylindrical body 7 as shown in FIG. 6 is not particularly limited, and for example, a polyolefin film having a thickness of about 0.05 to 0.10 mm is preferable. Can be used for.
Examples of the polyolefin include polyethylene and polypropylene.

[Examination of mattress types, covers, and seats]
Example 1, Comparative Examples 1 to 4
The material of the cover 20 of the tri-fold mattress (multi-fold cushion body) shown in FIG. 2 is a polyester woven fabric, and the sheet is a non-woven fabric of polyester, polyolefin or polyurethane having a grain size of 15 g / m ² , as shown in FIG. Example 1 was set in which compression and winding were performed by the compression winding device 10. The cushioning materials 211, 212, and 213 stored in the mattress are flexible polyurethane foams. In addition, Comparative Example 1 is a flexible polyurethane foam composed of one mattress without a cover, Comparative Example 2 is a mattress with a cover (woven cloth), and a cover (woven cloth) is used for a tri-fold mattress. The only ones were designated as Comparative Examples 3 and 4.
Tables 1 and 2 also show the results of examining the take-up property of the cover 20 with respect to the material.

[Examination of sheet material and windability]
Examples 2-4, Comparative Examples 5-8
The cover 20 of the tri-fold mattress (multi-fold cushion body) shown in FIG. 2 is made of polyester woven cloth, and the mattress is covered with the sheet 3 (grain size 15 g / m ² ) of the material shown in Table 3. The compression and winding were performed using the compression winding device 10 as shown in the above. The cushion bodies 211, 212, and 213 stored in the mattress are made of flexible polyurethane foam.
Table 3 shows the results of examining the types of sheet 3 and the rewindability.

[Examination of sheet weight and windability]
Examples 5-9, Comparative Example 9
The sheet was compressed and wound in the same manner as in Example 1 except that the basis weight of the sheet of Example 1 was changed as shown in Table 4.
Table 4 shows the results of examining the types of sheet 3 and the winding property.

カバーをポリエステル以外のポリオレフィン、麻、ナイロン、ポリ塩化ビニル、レーヨン、キュプラ等にした場合も同様の結果であった。

Similar results were obtained when the cover was made of polyolefin other than polyester, hemp, nylon, polyvinyl chloride, rayon, cupra, or the like.

INDUSTRIAL APPLICABILITY The present invention can be suitably used as a compression packing method for efficiently performing storage and transportation in a bulky multi-fold cushion body.

2 Multiple fold cushion body 20 Cover 201 Bag-shaped member 202 Connecting part 203 Openings 211, 212, 213 Cushion material 3 Sheet 7 Omitted columnar body 10 Compression winding device 40 Compression roll 50 Feed roll 501 Approximately cylindrical body 51 Cylindrical member 60 Conveying belt 71 Bag 81 Claw-shaped protrusion s Internal space of feed roll d Approximately columnar body diameter h Approximately columnar body height x Cushion body width y Cushion body length z Cushion body height (thickness) )

Claims (3)

A cushioning material is housed in each bag-shaped member of a cover formed by connecting a plurality of bag-shaped members, and at least a part of one side or both sides of a multi-fold cushion body foldable at the connecting portion. After compressing while covering with a non-woven fabric sheet
The compressed body is transferred to the internal space of a substantially cylindrical body formed by arranging a plurality of feed rolls at intervals in the generatrix direction, and is wound by the rotation of the plurality of feed rolls. Wind up in a spiral, then
It is a compression packing method of a multi-fold cushion body that is packed in a bag set at the outer end of a tubular member installed at one open end of the internal space while maintaining the spiral shape.
A method for compressing and packing a cushion body, wherein the sheet is made of synthetic fiber monofilament or multifilament and has a basis weight of 8 to 30 g / m ² . The compression packing method for a multi-fold cushion body according to claim 1, wherein the multi-fold cushion body is compressed in a state where one side is covered with a sheet and the sheet is folded in half so as to be on the outside. The compression packing method for a multi-fold cushion body according to claim 1 or 2, wherein the seat is installed so as to straddle at least a part of adjacent cushion materials of the multi-fold cushion body.

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