JP7313411B2 - Mattresses, manufacturing methods, disposal methods, and nonwoven sheets - Google Patents

Description

The present disclosure relates to mattresses, methods of manufacture, methods of disposal, and nonwoven sheets.

There is known a mattress that realizes a pocket coil by housing a coil spring in a bag-like body that forms a pocket space. In this type of mattress, a technique is known in which the sides of bag-shaped bodies prepared separately for each coil spring are adhered to each other, perforations are provided in the direction of the waist of each bag-shaped body, and the upper surface of the bag-shaped body is adhered to the lower surface of the mounting unit with an adhesive (see, for example, Patent Document 1). In this technique, by pulling the mounting unit upward, the perforations of the bag-shaped body are broken and the entire upper surface of each bag-shaped body is opened, making it possible to easily take out the coil spring.

JP 2012-95785 A

However, in the prior art as described above, it is necessary to cut a piece of cloth and form a bag-like body separately for each coil spring, which raises the problem of high manufacturing costs. In addition, since the bag-shaped bodies are individually formed, erroneous assembly is likely to occur when arranging a plurality of them. If breakage does not occur at some of the perforations of the bag-shaped body due to such incorrect assembly, it affects the entire bag, and there is a risk that all the perforations cannot be broken at the same time in a desired manner.

On the other hand, when forming a plurality of pocket spaces without cutting from a single piece of cloth, although it is possible to solve some of the above-mentioned problems in the case of forming individual bag-like bodies, it is difficult to form perforations that allow the plurality of pocket spaces to be easily opened because the plurality of pocket spaces are continuous with the cloth.

Therefore, an object of the present disclosure is to form a plurality of pocket spaces without cutting from a single piece of cloth in a mattress, and to provide perforations to the cloth that facilitate opening of the plurality of pocket spaces.

In one aspect, a mattress having pocketed coils comprising:
a coil spring forming the pocket coil;
a first cloth forming a pocket space for accommodating the coil spring;
a second cloth extending in a plane so as to cover the entire pocket space and fixed to the first cloth;
The first cloth is provided one by one for each row of the pocket spaces,
The first cloth has perforations continuous in a first direction on both sides of the plurality of pocket spaces,
A mattress is provided wherein the second fabric has cuts along the first direction.

According to the present disclosure, in a mattress, it is possible to form a plurality of pocket spaces without cutting from a single piece of cloth, and to provide the cloth with perforations that facilitate opening of the plurality of pocket spaces.

It is a perspective view which shows the use condition of a mattress. It is explanatory drawing of the cross-sectional structure of the mattress by Example 1, and is a schematic of the cross-sectional structure of a mattress. FIG. 4 is a schematic diagram of a cross-sectional structure of a mattress according to another embodiment; FIG. 4 is a top view schematically showing an arrangement mode of coil springs in a spring coil layer; FIG. 4 is an explanatory diagram of a nonwoven fabric that forms pocket spaces in which coil springs are accommodated; FIG. 4 is an explanatory diagram of a nonwoven fabric that forms pocket spaces in which coil springs are accommodated; It is explanatory drawing of a roll-shaped nonwoven fabric. FIG. 4 is a plan view of a nonwoven fabric forming pocket spaces in which each of a plurality of coil springs in one row is accommodated; FIG. 2 is an explanatory diagram of a method of forming pocket spaces from the nonwoven fabric according to Example 1; 3 is a side view of three pocket spaces extracted from among a plurality of pocket spaces in one row according to Embodiment 1 and viewed in the Y direction. FIG. 3 is a side view of three pocket spaces extracted from among a plurality of pocket spaces in one row and viewed in the X direction. FIG. FIG. 8 is a schematic cross-sectional view along line AA in FIG. 7; FIG. 8 is a schematic cross-sectional view along line BB in FIG. 7; It is an explanatory view of the disposal method, and is a perspective view showing a state in which the upper portion of the pocket space is open. It is explanatory drawing of the cross-sectional structure of the mattress 20B by Example 2, and is a schematic of the cross-sectional structure of a mattress. FIG. 10 is a side view of three pocket spaces extracted from among a plurality of pocket spaces in one row of the mattress according to Example 2 and viewed in the Y direction. FIG. 10 is a side view of three pocket spaces extracted from among a plurality of pocket spaces in one row of the mattress according to Example 2 and viewed in the X direction. FIG. 4 is a perspective view of the pocket coil layer as viewed from below; FIG. 4 is an explanatory diagram of the arrangement of cuts; FIG. 11 is an explanatory diagram (part 1) of a method of discarding a mattress according to Example 2; FIG. 11 is an explanatory diagram (part 2) of a method of discarding a mattress according to Example 2;

Each embodiment will be described in detail below with reference to the accompanying drawings. Note that the dimensional ratios in the drawings are merely examples, and the present invention is not limited to these, and shapes and the like in the drawings may be partially exaggerated for convenience of explanation. In the present specification, one piece of cloth such as nonwoven fabric means one piece (piece) in a product state, and is a concept including a multi-layer structure as long as the layers are integrated.

FIG. 1 is a perspective view showing how the mattress 20 is used. In FIG. 1, the X, Y and Z axes are defined in a right-handed coordinate system. In the following description, the up-down direction (Z direction) is based on the state of use of the mattress 20 . The mattress 20 is bedding and is placed on the bed frame 7 for use. Also, the mattress 20 can be changed up and down, but the upper and lower sides of the mattress 20 are based on the state shown in FIG. 1 unless otherwise specified. It should be noted that in the case of mattresses that are not reversible (see, for example, mattress 20A in FIG. 2A), logos or the like may be applied to the sides of the mattress to make the top side clear to the user.

FIG. 2 is an explanatory diagram of the cross-sectional structure of the mattress 20 and a schematic diagram of the cross-sectional structure of the mattress 20. As shown in FIG. FIG. 3 is a schematic top view showing the arrangement of the coil springs 223a and 223b in the spring coil layer 223. As shown in FIG. FIG. 3 defines an X direction (an example of a first direction) and a Y direction (an example of a second direction) similar to those in FIG. 1, where the longitudinal direction of the mattress 20 corresponds to the X direction.

In the example shown in FIG. 2, the mattress 20 consists of a quilting portion 21 (hereinafter also referred to as “upper quilting portion 21” for distinction), a padding portion 22, and a quilting portion 23 (hereinafter also referred to as “lower quilting portion 23” for distinction).

The upper quilting portion 21 is composed of a surface fabric 211, artificial cotton 212, soft urethane 213, and nonwoven fabric 214 from the top. The configuration of the upper quilting portion 21 is not limited to this, and other materials may be added or some materials may be omitted.

The surface fabric 211 may be, for example, a knitted fabric having antibacterial, deodorant, and antimite functions. The surface fabric 211 preferably has a density of 180 g/m ² or more. The surface fabric 211 may have a thickness of 1 mm, for example.

Synthetic cotton 212 may, for example, have a density of about 140 g/m ² . Also, the artificial cotton 212 may have a thickness of 10 mm, for example.

The soft urethane 213 may have a density of D28, for example. Also, the soft urethane 213 may have a thickness of 15 mm, for example.

The nonwoven fabric 214 may, for example, have a density of about 40 g/m ² . Also, the nonwoven fabric 214 may have a thickness of 0.25 mm, for example.

The stuffing portion 22 is composed of nonwoven fabric 220, soft urethane 221, nonwoven fabric 222, spring coil layer 223, nonwoven fabric 224, soft urethane 225, and nonwoven fabric 226 from the top.

The non-woven fabric 220 may, for example, have a density of about 40 g/m ² . Also, the nonwoven fabric 220 may have a thickness of 0.25 mm, for example.

The soft urethane 221 may, for example, have a density of D21. Also, the soft urethane 221 may have a thickness of 20 mm, for example. The soft urethane 221 may have an uneven top surface. This improves the body pressure dispersion value.

Nonwoven fabric 222 may, for example, have a density of about 80 g/m ² . Also, the nonwoven fabric 222 may have a thickness of 0.25 mm, for example.

In the spring coil layer 223, a plurality of coil springs 223a and 223b forming pocket coils are arranged in parallel. Each row of the coil springs 223a, 223b extends in the longitudinal direction (X direction) of the mattress 20 and contacts each other in the lateral direction (Y direction) of the mattress 20. As shown in FIG. The number of coil springs 223a, 223b in each row may be the same. In addition, in a modification, a plurality of coil springs 223a may be arranged in an alternate arrangement.

In this embodiment, as an example, as shown in FIG. 3, when the first to seventh rows are arranged in order from the top in the lateral direction (Y direction), the third to fifth rows are composed of a plurality of coil springs 223a, and the other rows are composed of a plurality of coil springs 223b. In this way, by using the two types of coil springs 223a and 223b, it is possible to effectively improve sleeping comfort. However, in a modified example, one or three more types of coil springs may be used.

The coil spring 223a forming the spring coil layer 223 has a wire diameter (steel wire diameter) of 1.8 mm and a coil diameter of 62 mm. The coil spring 223a forming the spring coil layer 223 has 5 turns, a free coil height of 170 mm, and a pocket height of 100 mm. Each coil spring 223a may be, for example, a lantern shape.

The coil spring 223b forming the spring coil layer 223 has a wire diameter (steel wire diameter) of 2.2 mm and a coil diameter of 62 mm. The coil spring 223b forming the spring coil layer 223 has 5.5 turns, a free coil height of 140 mm, and a pocket height of 100 mm. Each coil spring 223b may be, for example, a lantern shape.

The non-woven fabric 224 may, for example, have a density of about 80 g/m ² . Also, the nonwoven fabric 224 may have a thickness of 0.25 mm, for example.

Soft urethane 225 may, for example, have a density of D21. Also, the soft urethane 225 may have a thickness of 15 mm, for example.

The nonwoven fabric 226 may, for example, have a density of about 40 g/m ² . Also, the nonwoven fabric 226 may have a thickness of 0.25 mm, for example.

The lower quilted portion 23 is composed of nonwoven fabric 231, soft urethane 232, artificial cotton 233, and surface fabric 234 from the top. The configuration of the lower quilting portion 23 is not limited to this, and other materials may be added or some materials may be omitted.

The non-woven fabric 231 may, for example, have a density of about 40 g/m ² . Moreover, the nonwoven fabric 231 may have a thickness of 0.25 mm, for example.

The soft urethane 232 may, for example, have a density of D28. Also, the soft urethane 232 may have a thickness of 15 mm, for example.

Synthetic cotton 233 may, for example, have a density of about 140 g/m ² . Also, the artificial cotton 233 may have a thickness of 10 mm, for example.

The surface fabric 234 may be, for example, a knitted fabric having antibacterial, deodorant, and antimite functions. The face fabric 234 preferably has a density of 180 g/m ² or higher. The surface fabric 234 may be, for example, 1 mm thick.

Although FIG. 2 shows the mattress 20 having a specific configuration, the mattress 20 may have any configuration as long as it has the spring coil layer 223 and the spring coil layer 223 has the configuration described later. For example, it may be a mattress 20A configured as shown in FIG. 2A. In this case, instead of the soft urethane 232, a needle punch 232A or the like is used. Such a mattress 20A is suitable for use in which the vertical direction is not changeable (that is, use in which the positive side in the Z direction is always the upper side).

Next, the details of the spring coil layer 223 will be described with reference to FIG. 4A and subsequent drawings. Although the configuration of the row associated with the coil spring 223a will be described below as a representative, the same applies to the row associated with the coil spring 223b.

FIGS. 4A to 4C are explanatory diagrams of the nonwoven fabric 250 (an example of the first fabric) forming the pocket space S1 in which each of the coil springs 223a is accommodated.

The nonwoven fabric 250 may be formed from a plurality of rectangular nonwoven fabric sheets 25 when unfolded. For example, the perforations 252 of the nonwoven fabric 250 may be formed by a perforation forming blade 400 (only one shown in FIG. 4A) when unwinding the nonwoven fabric sheet 25 in a rolled form, as shown in FIG. 4A. Two perforations 252 are formed in parallel, as shown in FIG. 4A. The perforation forming blade 400 may have a blade length of, for example, about 3 mm, and the blades may be arranged periodically at intervals of 1 mm along the circumferential direction. The nonwoven fabric 250 with the perforations 252 thus formed may be wound into a roll and managed as shown in FIG. 4C. In this case, the roll direction of the nonwoven fabric sheet 25 may correspond to the X direction shown in FIG. 3 and the like.

Alternatively, as shown in FIG. 4B, the nonwoven fabric 250 may be formed by cutting a single nonwoven fabric sheet 25 for forming a plurality of nonwoven fabrics 250 and making perforations 252 at the same time. Such cuts and provision of perforations 252 may be realized when unwinding the nonwoven fabric sheet 25 wound into a roll. As a result, an efficient manufacturing process can be realized as compared with the case where the process of forming the perforations 252 is provided separately. When cutting a single nonwoven fabric sheet 25 for forming a plurality of nonwoven fabrics 250 into a plurality of sheets, only cutting along the X direction corresponding to the unwinding direction is realized, and cutting in the Y direction (cutting in the cross direction) may be performed separately. FIG. 4B schematically shows perforations 252 and cut lines 253 formed on one nonwoven fabric sheet 25 for forming four nonwoven fabrics 250 . Also in this case, the nonwoven fabric 250 that has been cut and formed with perforations 252 may be wound into a roll and managed or transported, as shown in FIG. 4C.

As described above, when the length in the X direction of the nonwoven fabric sheet 25 wound into a roll after the perforations 252 are formed has the length of a plurality of nonwoven fabrics 250, each of the nonwoven fabrics 250 may be formed by cutting along the Y direction for each length along the X direction.

FIG. 5 is a plan view of a nonwoven fabric 250 forming pocket spaces S1 in which a plurality of coil springs 223a in one row (eleven coil springs 223a in FIG. 3) are accommodated. FIG. 5 shows the unfolded nonwoven fabric 250 before forming the pocket space S1. In FIG. 5, the dashed-dotted line L1 represents the centerline of the nonwoven fabric 250 in the Y direction, and the hatched portions at the upper and lower ends correspond to welded portions 258, which will be described later. 6A and 6B are explanatory diagrams of a method of forming the pocket space S1 from the nonwoven fabric 250. FIG. FIG. 7 is a side view of three pocket spaces S1 extracted from one row of a plurality of pocket spaces S1 and viewed in the Y direction. 7 schematically shows the coil spring 223a in the pocket space S1 formed by the nonwoven fabric 250 for explanation purposes. In FIG. 7 (the same applies to FIGS. 8 and 9 below), the welding portions 256 and 258 and the adhesives 80, 82 and 84 are schematically indicated by hatching. FIG. 8 is a side view of three rows of pocket spaces S1 that are adjacent in the Y direction and viewed in the X direction. FIG. 8 also schematically shows the coil spring 223a in the pocket space S1 formed by the nonwoven fabric 250 for explanation. 7 and 8 also show nonwoven fabrics 222, 224 on the upper and lower sides of the pocket space S1. 9 is a schematic cross-sectional view along line AA of FIG. 7, and FIG. 10 is a schematic cross-sectional view along line BB of FIG. Line BB in FIG. 7 is shown slightly shifted from perforation 252 for the sake of explanation, but it is a line along perforation 252 . FIG. 11 is an explanatory diagram of the disposal method, and is a perspective view showing a state in which the upper portion of the pocket space S1 is opened.

The nonwoven fabric 250 has two perforations 252 parallel to the X direction, as shown in FIG. In the unfolded state of the nonwoven fabric 250, the distance between the perforations 252 in the Y direction is a predetermined interval corresponding to the size of the pocket space S1, specifically significantly larger than the outer diameter (diameter of the largest portion) of the coil spring 223a.

When forming each row of the coil spring assembly (an assembly consisting of the nonwoven fabric 250 and the coil springs 223a integrated by the welded portions 256 and 258), as schematically shown in FIG. At this time, each coil spring 223a is positioned with respect to the sheet of nonwoven fabric 250 so that a line segment connecting the coil center axes of each coil spring 223a (see one-dot chain line L2 in FIG. 6) is approximately the center (the center in the Y direction) between the two perforations 252.

From the state in which the nonwoven fabric 250 and the plurality of coil springs 223a are set in this way, the nonwoven fabric 250 is folded back so that both ends of the nonwoven fabric 250 in the Y direction overlap each other, so that the plurality of coil springs 223a are wrapped in the nonwoven fabric 250. At this time, the two perforations 252 continuous in the X direction are positioned on both sides of the plurality of coil springs 223a in the Y direction.

A welded portion 258 is formed by welding both ends of the nonwoven fabric 250 in the Y direction. That is, the nonwoven fabric 250 associated with one row has welded portions 258 (an example of second welded portions) that join end portions to each other on one side in the Y direction of the pocket spaces S1 associated with one row. In addition, a welded portion 256 (an example of a first welded portion) is formed in a mode that partitions the pocket spaces S1 related to the coil springs 223a that are adjacent in the X direction. Note that the welded portions 256 may also be formed at both ends in the X direction of the nonwoven fabric 250 associated with one row. In the example shown in FIG. 6, the welded portions 256 are welded as the welded portions 256 in the nonwoven fabric 250 as indicated by 256-1 to 256-3. In this case, the pair of locations 256-1 are welded together to form one welded portion 256, the paired locations 256-2 are welded together to form another welded portion 256, and the paired locations 256-3 are welded together to form yet another welded portion 256.

As shown in FIG. 8, each row of the coil spring assembly (an assembly consisting of the nonwoven fabric 250 and the coil springs 223a integrated by the welded portions 256 and 258) formed in this manner is joined at the Y-direction sides with an adhesive 80. 7 and 8, each row of coil spring assemblies is bonded to the upper nonwoven fabric 222 extending in the XY plane with an adhesive 82, and is bonded to the lower nonwoven fabric 224 extending in the XY plane with an adhesive 84. The nonwoven fabric 222 is common to all the coil springs 223a and 223b in one mattress 20, and is adhered (fixed) to the nonwoven fabric 250 forming the pocket spaces S1 of each row. By providing such a nonwoven fabric 222, even when a local load (external load) is applied between the pocket spaces S1 in a direction perpendicular to the surface of the mattress 20, local sinking (sinking between the pocket spaces S1) can be prevented. This also applies to the nonwoven fabric 224 .

According to this embodiment, one sheet of the nonwoven fabric 250 is used for each row to form the pocket spaces S1 for each row, so there is no need to cut the nonwoven fabric 250 to form each pocket space S1, thereby greatly improving productivity.

Further, according to this embodiment, as described above, the nonwoven fabric 250 associated with one row has perforations 252 continuous in the X direction on both sides of each pocket space S1 associated with one row in the Y direction. Also, as shown in FIG. 10, the two perforations 252 are positioned substantially at approximately the same height, and are continuous in the X direction in a manner surrounding each coil spring 223a when viewed from above. The perforations 252 are formed at a pitch that does not break due to the repulsive force of each coil spring 223a. In this embodiment, as described above, the perforations 252 are formed by periodically arranging holes having a length of about 3 mm in the X direction at intervals of 1 mm (that is, a pitch of 4 mm).

In this embodiment, since the nonwoven fabric 222 is adhered to the nonwoven fabric 250 with the adhesive 82, when the nonwoven fabric 222 is pulled against the spring coil layer 223 in the direction of peeling off the spring coil layer 223 when the mattress 20 is discarded, a large force (significantly larger force than the repulsive force of each coil spring 223a) is applied to the perforations 252 of the nonwoven fabric 250. As a result, the perforations 252 in each row are continuously broken. In this way, according to this embodiment, the upper side of each pocket space S1 (above the perforation 252) can be easily opened to the pocket space S1 of each row (see FIG. 11). Hereinafter, when the mattress 20 is discarded, the operation of tearing off the nonwoven fabric 222 from the spring coil layer 223 to break the perforations 252 of the nonwoven fabric 250 and open the upper side of each pocket space S1 is simply referred to as "nonwoven fabric peeling work".

Also, according to this embodiment, as described above, in the unfolded state of the nonwoven fabric 250, the distance between the perforations 252 in the Y direction is greater than the outer diameter of the coil spring 223a. Therefore, when the coil spring 223a is accommodated in the pocket space S1, as shown in FIGS. 7 and 8, the perforations 252 are formed below the uppermost winding 2231 of the coil spring 223a, above the lowermost winding 2232 of the coil spring 223a, and biased upward from the axial center of the coil spring 223a. For example, as shown in FIG. 7, the distance Δ1 of the perforations 252 from the upper surface of the pocket space S1 may be in the range of 12mm to 18mm. As a result, when the perforations 252 are broken by pulling the nonwoven fabric 222 from the spring coil layer 223, the possibility that the part of the nonwoven fabric 250 above the perforations 252 is caught by the coil springs 223a is reduced. When breaking the perforations 252 by pulling the nonwoven fabric 222 from the spring coil layer 223, if the portion of the nonwoven fabric 250 above the perforations 252 is caught by the coil springs 223a, part of the force pulling the nonwoven fabric 222 is applied to the coil springs 223a, and the force required to break the perforations 252 increases accordingly. On the other hand, according to the present embodiment, the perforation 252 can be broken with a relatively low force, and workability when opening the upper side of each pocket space S1 (that is, workability of peeling off the nonwoven fabric) can be improved.

If the perforation 252 is positioned below the axial center of the coil spring 223a, even when the perforation 252 is broken and the portion of the nonwoven fabric 250 above the perforation 252 is removed together with the nonwoven fabric 222, the portion of the nonwoven fabric 250 above the perforation 252 may be caught by the coil spring 223a. Such catching deteriorates workability. In this regard, according to the present embodiment, such inconvenience is less likely to occur, and workability when opening the upper side of each pocket space S1 (that is, workability of peeling off the nonwoven fabric) can be enhanced.

In addition, according to the present embodiment, as described above, in the unfolded state of the nonwoven fabric 250, the distance between the perforations 252 in the Y direction is greater than the outer diameter of the coil spring 223a. Therefore, when the pocket space S1 is open on the upper side, the coil spring 223a can be easily taken out through the opening on the upper side of the pocket space S1. That is, it is possible to improve workability when removing the coil spring 223a.

In this embodiment, the welded portion 256 is preferably formed along the vertical direction so as to terminate before the perforation 252 in the vertical direction, as shown in FIG. In this embodiment, the welded portions 256 formed between the two pocket spaces S1 in the X direction are vertically divided into three, but the number may be larger or smaller. Also, the welded portion 256 formed between the two pocket spaces S1 in the X direction may be formed in a continuous manner in the vertical direction.

In this way, in this embodiment, the welded portion 256 that partitions the pocket space S1 in the X direction is arranged below the perforation 252. Therefore, compared to the case where the perforated portion 252 is included in the welded portion 256 (i.e., the perforation 252 is welded to form the welded portion 256), workability in breaking the perforation 252 is improved. That is, since the range above the perforations 252 (the range in the vertical direction) is relatively narrow, if the perforations 252 are also welded above the perforations 252, the perforations 252 may be welded together in the Y direction. On the other hand, since the range below the perforation 252 (the range in the vertical direction) is relatively wide, if only the area below the perforation 252 is welded, the possibility of the perforations 252 being welded together in the Y direction as shown in FIG. 10 is low. That is, it is possible to reduce the possibility that the perforations 252 are welded together in the Y direction while ensuring the necessary welding range in the vertical direction. If the perforations 252 are welded together in the Y direction, the force required to continuously break the perforations 252 may be excessive. Therefore, according to this embodiment, it is possible to reduce the possibility that the force required to continuously break the perforations 252 will be excessive due to the welded portion 256 .

In addition, in this embodiment, the perforations 252 are located above the welding portions 258 that join the Y-direction ends of the nonwoven fabric 250, as schematically shown in FIG. This improves workability when breaking the perforations 252 compared to the case where the perforations 252 are included in the welded portion 258 (that is, the perforations 252 are welded to form the welded portion 258). That is, the force required for breaking can be appropriately reduced.

4A and later, one sheet of nonwoven fabric 250 is used for each row of pocket spaces S1 arranged in the X direction, but one sheet of nonwoven fabric 250 may be used for each row of pocket spaces S1 arranged in the Y direction. Such a configuration is a configuration obtained by replacing the X direction and the Y direction with the Y direction and the X direction in the description of FIG. 4A and subsequent figures (including the following description of FIG. 12 and subsequent figures). Substantially the same effect can be obtained in this case as well.

Next, another embodiment will be described with reference to FIG. 12 and subsequent figures. Hereinafter, for convenience of explanation, the above-described embodiment will be referred to as "embodiment 1", and the embodiments after FIG. 12 will be referred to as "embodiment 2". In the description of the second embodiment, constituent elements that may be the same as those of the first embodiment described above may be given the same reference numerals and the description thereof may be omitted.

FIG. 12 is an explanatory diagram of the cross-sectional structure of the mattress 20B according to this embodiment, and is a schematic diagram of the cross-sectional structure of the mattress 20B. FIG. 13 is a side view of three pocket spaces S1 extracted from a plurality of pocket spaces S1 in one row of the mattress 20B according to the present embodiment and viewed in the Y direction. FIG. 14 is a side view of three pocket spaces S1 extracted from a plurality of pocket spaces S1 in one row of the mattress 20B according to the present embodiment and viewed in the X direction. FIG. 15 is a perspective view of a portion of the mattress 20B made up of the nonwoven fabric 224B, the spring coil layer 223B, and the nonwoven fabric 222 (hereinafter also referred to as "pocket coil layer 2") viewed from below. FIG. 16 is an explanatory diagram of the positions of the cuts 29 in the X direction with respect to the row of the pocket spaces S1 in the X direction, and is a top view showing the lower part when cut along the XY plane passing through the center of the coil spring 223a in the axial direction, together with the dotted line 290 indicating the line where the cuts 29 are provided.

A mattress 20B according to this embodiment differs from the mattress 20A shown in FIG. 2A in that the spring coil layer 223 is replaced with a spring coil layer 223B, and the nonwoven fabric 224 is replaced with a nonwoven fabric 224B (an example of a second fabric). Also, in this embodiment, the nonwoven fabric to be peeled off from the spring coil layer 223B in the nonwoven fabric peeling operation is the nonwoven fabric 224B, which is different from the above-described embodiment in which the nonwoven fabric to be peeled off from the spring coil layer 223B in the peeling operation is the nonwoven fabric 222.

The spring coil layer 223B of this embodiment differs from the spring coil layer 223 of the above-described embodiment in the number of pocket spaces S1 (and the number of rows of pocket spaces S1). Note that this embodiment is suitable when the number of rows of the coil springs 223a (the number of rows related to rows arranged in the X direction) is relatively large. As an example, the spring coil layer 223B of this embodiment has 24 rows of pocket spaces S1, and each of the 24 rows includes 20 pocket spaces S1 arranged in the X direction.

Further, in the spring coil layer 223B of the present embodiment, the perforations 252 are formed below the uppermost winding 2231 of the coil spring 223a, above the lowermost winding 2232 of the coil spring 223a, and biased below the center of the coil spring 223a in the axial direction. In other words, the spring coil layer 223B of this embodiment has a configuration in which the configuration related to the nonwoven fabric 250 is upside down with respect to the spring coil layer 223 of the above-described embodiment.

The nonwoven fabric 224B of this embodiment differs from the nonwoven fabric 224 of the first embodiment described above in that the nonwoven fabric 224B has cuts 29 along the same X direction as the direction in which the perforations 252 extend.

The cut 29 is formed continuously along the X direction. The cuts 29 may be in the form of perforations that do not separate the nonwoven fabrics 224B in the Y direction, but are preferably in the form of continuous cuts that separate the nonwoven fabrics 224B in the Y direction. In this embodiment, by way of example, the cut 29 is in the form of a continuous cut.

The cuts 29 have the function of enhancing the workability of the nonwoven fabric peeling work described above. Specifically, since the nonwoven fabric 224B has the slits 29, it is not necessary to peel off the entire nonwoven fabric at once when peeling off the nonwoven fabric. In other words, the nonwoven fabric 224B can be peeled off for each region (section) separated by the cuts 29 . As a result, the peeling force does not become excessive, and the workability of the nonwoven fabric peeling work can be effectively improved. Further details of this feature are provided below. It should be noted that the nonwoven fabric 222 may not have cuts such as the cuts 29 .

From the viewpoint of effectively improving the workability of the nonwoven fabric peeling work, the cut 29 preferably extends from one side end to the other side end in the X direction as shown in FIG. 15 . That is, the cuts 29 are formed in a manner that divides the nonwoven fabric 224B into a plurality of independent sections in the Y direction. However, in a modified example, the cut 29 may be formed so as to terminate before one of the ends in the X direction. That is, the cut 29 may terminate at one end of the nonwoven fabric 224B in the X direction, leaving a predetermined length. In this case, the cut 29 may be formed at one end of the nonwoven fabric 224B in the X direction so as to terminate on the one side in the X direction from the pocket space S1 on the farthest one side in the X direction. In addition, the predetermined length may be relatively small, for example, 20 mm or less.

The number of cuts 29 may be one, but when the number of rows of pocket spaces S1 in the X direction is relatively large as in the present embodiment, preferably a plurality of cuts 29 are provided in a manner spaced apart from each other in the Y direction. That is, a plurality of cuts 29 may be formed parallel to each other along the X direction while being separated from each other in the Y direction. In this case, the interval between the cuts 29 adjacent in the Y direction is larger than the Y-direction length of one row of the X-direction pocket spaces S1, that is, the outer diameter (diameter of the maximum portion) of the coil spring 223a, and more preferably longer than the Y-direction length of two rows of the X-direction pocket spaces S1. Further, the cut 29 is formed between two specific rows adjacent in the Y direction among the plurality of rows (rows of the pocket spaces S1 in the X direction) when viewed from above. In this embodiment, as shown in FIGS. 15 and 16, a plurality of sets of specific two columns are periodically set in the Y direction. That is, the cuts 29 are formed at approximately equal intervals in the Y direction between the edges 255 on both sides in the Y direction, including the first cut 29 from the edge 255 . Specifically, the cut 29 is provided every three rows and formed between two specific adjacent rows every three rows. As will be described later, if the cuts 29 are formed after the nonwoven fabric 224B is adhered to the nonwoven fabric 250 with the adhesive 84, the pitch of the cuts 29 in the Y direction may not be strictly constant. Therefore, regarding the distance between the cuts 29 in the Y direction, the term "substantially equal intervals" is a concept that allows for such an error.

Note that, in this embodiment, as an example, the nonwoven fabric 224B is substantially divided into eight separated regions (sections), which are arranged in eight rows in the X direction. In this case, one row of the nonwoven fabric 224B covers three rows of the pocket spaces S1 in the X direction.

The manufacturing method of the mattress 20A according to this embodiment may be basically the same as the manufacturing method of the mattress 20 according to the first embodiment described above. In this case, the cuts 29 related to the nonwoven fabric 224B may be formed after the nonwoven fabric related to the nonwoven fabric 224B (nonwoven fabric without cuts 29) is fixed to the spring coil layer 223B with the adhesive 84. In this case, productivity can be improved compared to the case where the nonwoven fabrics 224B that have been cut in advance by the cuts 29 are individually fixed to the spring coil layers 223B.

Next, with reference to FIGS. 17 and 18, the function of the cut 29 (the function of improving the workability of peeling off the nonwoven fabric) and the disposal method of the mattress 20B will be described.

17 and 18 are explanatory diagrams of the disposal method of the mattress 20B, and FIG. 17 shows the initial state S1700 of the disposal method and the execution state S1702 of the non-woven fabric stripping work related to the first sheet of the non-woven fabric 224B. In FIG. 17, initial state S1700 and execution state S1702 are shown in a perspective view of pocket coil layer 2 (portion of nonwoven fabric 224B, spring coil layer 223B, and nonwoven fabric 222) of mattress 20B viewed from below. FIG. 18 shows a state S1704 in which the third nonwoven fabric 224B is peeled off, and a state S1706 in which the nonwoven fabric 224B is peeled off, as viewed from below in a perspective view similar to FIG.

Also in this embodiment, the method of discarding the mattress 20B is realized in substantially the same manner as the method of discarding the mattress 20 of the above-described embodiment. That is, the method of discarding the mattress 20B includes a work of tearing off the nonwoven fabric 224B from the spring coil layer 223B to break the perforations 252 of the nonwoven fabric 250 to open the upper side of each pocket space S1 (that is, a nonwoven fabric tearing work), and a work of removing the coil springs 223a and 223b from the upper side of each opened pocket space S1. Although these operations are performed manually, some or all of these operations may be performed by robots.

According to this embodiment, as shown in FIGS. 17 and 18, the nonwoven fabric 224B has the cuts 29 in the X direction, so that the workability of peeling off the nonwoven fabric can be effectively improved. Specifically, the operator first removes the portion other than the pocket coil layer 2 (such as the surface cloth 234A) from the mattress 20B to be discarded, leaving only the pocket coil layer 2, and turns the pocket coil layer 2 upside down to form an initial state S1700 in which the nonwoven fabric 224B of the pocket coil layer 2 is on the upper side. Next, from the initial state S1700, the worker pulls the endmost row of the nonwoven fabric 224B upward using the end cut 29 (see arrow R170). The operator repeats such work for each row of the nonwoven fabric 224B (see execution state S1704 in FIG. 18) to form a state S1706 in which all rows of the nonwoven fabric 224B (that is, the entire nonwoven fabric 224B) are peeled off, and the nonwoven fabric stripping operation is completed. After finishing the nonwoven fabric peeling work, the worker takes out the coil springs 223a and 223b from the pocket spaces S1 opened above the perforations 252 (upper side for the worker).

By the way, if the bonding strength between the nonwoven fabric 250 and the nonwoven fabric 224B by the adhesive 84 is insufficient, it becomes difficult to effectively break the perforations 252 when peeling off the nonwoven fabric. For example, when the non-woven fabric is peeled off, the perforation 252 cannot be broken if the joint portion by the adhesive 84 is broken before the perforation 252 is broken. Therefore, the bonding strength between the nonwoven fabric 250 and the nonwoven fabric 224B by the adhesive 84 needs to be set relatively high so that the perforations 252 break first. On the other hand, however, if the bonding strength between the nonwoven fabric 250 and the nonwoven fabric 224B by the adhesive 84 is properly ensured, the force required to peel off the entire nonwoven fabric 224B at the same time may become excessive. In addition, if the nonwoven fabric 224B as a whole is relatively large and the adhesive 84 is applied to a large number of places accordingly, the force required to peel off the entire nonwoven fabric 224B at the same time may become excessive.

In contrast, according to the present embodiment, the nonwoven fabric 224B can be peeled off in rows divided by the cuts 29 instead of peeling off the entire nonwoven fabric 224B at the same time. As a result, the force required for peeling off the nonwoven fabric is not excessive, and the workability of the nonwoven fabric peeling work can be improved.

2, the spring coil layer 223 may be replaced with the spring coil layer 223B, and the nonwoven fabric 222 may be formed with cuts similar to the cuts 29 of the nonwoven fabric 224B. Alternatively, instead of or in addition to nonwoven fabric 222 , nonwoven fabric 224 may have cuts similar to cuts 29 .

As described above, the spring coil layer 223B of the present embodiment has a configuration in which the configuration related to the nonwoven fabric 250 is inverted upside down with respect to the spring coil layer 223 of the above-described embodiment, so the adhesive 80 may be applied only above the perforations 252, as shown in FIG. If the adhesive 80 is also applied below the perforations 252, the workability of peeling off the nonwoven fabric will be deteriorated. That is, when the adhesive 80 is also applied below the perforations 252, the force during the nonwoven fabric peeling operation extends to between the nonwoven fabrics 250 in adjacent rows in the Y direction (between the nonwoven fabrics 250 in adjacent rows via the cut 29) via the adhesive 80, so the force required to break the perforations 252 increases. On the other hand, as shown in FIG. 14, when the adhesive 80 is applied only above the perforations 252, the force of the nonwoven fabric peeling work does not significantly reach between the nonwoven fabrics 250 in adjacent rows via the cut 29 via the adhesive 80. As a result, the force required for peeling off the nonwoven fabric is not excessive, and the workability of the nonwoven fabric peeling work can be improved.

Although each embodiment has been described in detail above, it is not limited to a specific embodiment, and various modifications and changes are possible within the scope described in the claims. It is also possible to combine all or more of the constituent elements of the above-described embodiments.

For example, in the embodiment described above, the perforation 252 is formed at a position biased upward with respect to the vertical center of the coil springs 223a and 223b, but instead or in addition, the perforation 252 may be formed at a position biased downward from the vertical center of the coil springs 223a and 223b. In this case, it is possible to realize a configuration in which the perforations 252 are easily broken by pulling from the opposite side (that is, in the direction in which the lower nonwoven fabric 224 is peeled off from the spring coil layer 223). For example, when the mattress 20 can be moved vertically, if the perforations 252 are formed at a position biased upward with respect to the vertical center of the coil springs 223a and 223b and at a position biased downward with respect to the vertical center of the coil springs 223a and 223b, the user can pull the nonwoven fabric 222 or the nonwoven fabric 224 and break the upper or lower perforations 252 without being aware of the vertical direction of the mattress 20. Alternatively, the perforation 252 may be formed near the center of the coil springs 223a and 223b in the vertical direction (at a position where there is no deviation in the vertical direction).

Further, in the second embodiment described above with reference to FIG. 12 and subsequent figures, the cut line 29 is formed only along the same X direction as the perforation line 252, but the present invention is not limited to this. A cut in the Y direction (not shown) may be formed in a manner intersecting with the cut 29 formed along the X direction. In this case, the X-direction length of the regions (sections) separated by the cuts in the nonwoven fabric 224B is shortened by the Y-direction cuts.

In connection with the above disclosure, the following additional notes are further disclosed.

[Appendix 1]
A mattress having a plurality of pocket coils arranged along a first direction and a second direction perpendicular to each other in a plane perpendicular to the vertical direction,
coil springs forming individual pocket coils;
a first cloth forming a plurality of pocket spaces for accommodating the plurality of coil springs;
a second cloth that extends in a plane so as to cover the entirety of the plurality of pocket spaces from a first side in the vertical direction and is fixed to the first cloth;
The first cloth is provided in a plurality of rows, one for each row, for a plurality of rows of the pocket spaces arranged in the first direction,
Each of the plurality of first cloths has perforations continuous in the first direction on both sides of the plurality of pocket spaces in the second direction,
The mattress, wherein the second fabric has cuts along the first direction.

[Appendix 2]
2. The mattress of claim 1, wherein the cut extends from one end of the second fabric to the other end in the first direction.

[Appendix 3]
A plurality of the cuts are provided in a manner spaced apart from each other in the second direction,
3. The mattress according to appendix 1 or 2, wherein the cut is formed between two specific rows of the plurality of rows that are adjacent in the second direction when viewed from above.

[Appendix 4]
3. The mattress of claim 3, wherein the cuts are formed at substantially equal intervals in the second direction.

[Appendix 5]
Between the two adjacent cuts in the second direction, or between the edge of the second cloth in the second direction and the cut adjacent to the edge, in a top view, the mattress according to appendix 3 or 4, wherein two or more rows are provided.

[Appendix 6]
one sheet of the first cloth has a first welded portion that partitions each of the plurality of pocket spaces arranged in the first direction;
6. The mattress according to any one of appendices 1 to 5, wherein the first welded portion is formed along the vertical direction only on a second side opposite to the first side with respect to the perforations in the vertical direction.

[Appendix 7]
In the first cloths in each row, adjacent first cloths in the second direction are bonded to each other at side portions in the second direction,
7. A mattress according to any one of clauses 1 to 6, wherein the perforation is located on the first side of the adhered portion.

7 Bed frames 20, 20A, 20B Mattress 21 Upper quilting part 22 Filling part 23 Lower quilting part 25 Nonwoven fabric sheet 80 Adhesive 82 Adhesive 84 Adhesive 211 Surface fabric 212 Artificial cotton 213 Soft urethane 214 Nonwoven fabric 220 Nonwoven fabric 221 Soft urethane 222 Nonwoven fabric 223, 223B Spring coil layer 223a Coil spring 223b Coil spring 2 24, 224B Non-woven fabric 225 Soft urethane 226 Non-woven fabric 231 Non-woven fabric 232 Soft urethane 233 Artificial cotton 234 Surface fabric 250 Non-woven fabric 252 Perforation 256 Welded portion 258 Welded portion 400 Perforation forming blade 2231 Winding 2232 Winding

Claims (10)

A mattress having pocketed coils,
a coil spring forming the pocket coil;
a first cloth forming a pocket space for accommodating the coil spring;
a second cloth extending in a plane so as to cover the entire pocket space and fixed to the first cloth;
The first cloth is provided one by one for each row of the pocket spaces,
The first cloth has perforations continuous in a first direction on both sides of the plurality of pocket spaces,
The mattress, wherein the second fabric has cuts along the first direction. The cut extends from one end of the second cloth to the other end in the first direction,
A mattress according to claim 1 . A plurality of the cuts are provided in a manner spaced apart from each other in a second direction that intersects the first direction,
The break is formed between specific rows adjacent in the second direction among the plurality of rows in a top view,
3. A mattress according to claim 1 or 2. The perforation is formed at a position that is biased in the vertical direction toward the side closer to the second cloth than the axial center of the coil spring.
4. A mattress according to any one of claims 1-3. A method for manufacturing the mattress according to any one of claims 1 to 4,
affixing the second fabric to the first fabric;
and a step of making the cut in the second cloth fixed to the first cloth. A method for manufacturing the mattress according to any one of claims 1 to 4,
a preparation step of preparing the first cloth having the perforations;
between the perforations in a second direction that intersects the first direction in one of the first fabrics;
positioning a row of the coil springs in the pocket space;
By overlapping the ends of the first cloth in the second direction,
and wrapping the coil spring with the first cloth. In the preparation step, for one cloth for forming the first cloth for a plurality of sheets,
7. The manufacturing method according to claim 6, including the step of making the perforations at the same time as cutting for a plurality of sheets. A method for discarding a mattress according to any one of claims 1 to 4,
tearing the first cloth through the perforations by peeling the second cloth from the first cloth;
after the step, taking out the coil spring from the pocket space opened on a side closer to the second cloth than the perforation by tearing the first cloth. A nonwoven fabric sheet for a mattress having a plurality of pocket coils arranged along a first direction and a second direction perpendicular to each other in a plane perpendicular to the vertical direction,
It is in a form wound in a roll shape with the first direction as the roll direction,
A nonwoven fabric sheet, wherein at least two continuous perforations along the first direction are formed at predetermined intervals in the second direction. The predetermined interval is larger than the diameter of the coil spring forming the pocket coil,
The nonwoven fabric sheet according to claim 9.

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