Three-layer or five-layer mattress futon and its manufacturing method

Abstract

The objective is to provide a three-layer or five-layer mattress futon and a method for manufacturing the same, which do not have machine stitching that penetrates the cover material, in order to simplify the comfort sewing process. [Solution] The three-layer or five-layer mattress futon of the present invention is characterized in that a core and a roll of cotton wrapping the core are sandwiched between a bag-shaped cover material made of an outer fabric and an inner fabric, the roll of cotton is compressed and stored in the cover material, and the cover material as a whole receives tension due to the elastic force of the core and the roll of cotton, thereby maintaining the position of the stored roll of cotton and the core. Therefore, comfort stitching is not required.

Description

Technical Field

[0001] The present invention relates to a three-layer or five-layer mattress pad formed by combining a core and a rolled cotton, and having no sewing part by a comfort sewing machine or the like, and a method for manufacturing the same.

Background Art

[0002] As a mattress pad, for example, a mattress pad having a structure in which a plate-like core (or solid cotton) and rolled cotton arranged so as to cover the front and back surfaces of the core and forming a relatively soft contact surface is widely sold.

[0003] In addition, in a mattress pad having such a structure, comfort sewing is usually performed by a comfort sewing machine. After covering the core and the rolled cotton surrounding it with a cover material, sewing is performed so as to penetrate the cover material, and on the front and back surfaces of the mattress, for example, seams that go around at a predetermined interval from the end of the mattress are formed (see, for example, Patent Document 1).

[0004] Furthermore, a futon is also known in which a core material formed of hard cotton obtained by compressing the thickness of ordinary futon cotton by needle punching and soft cotton surrounding the core material are inserted into a futon cover (see, for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, while this type of comfort stitching has benefits such as preventing the core and the cotton batting from shifting inside the cover material and ensuring breathability, it requires a relatively large comforter sewing machine to process the futon mattress. The maintenance costs of this large machine and the sewing process itself are also high, so there was a need to simplify the process.

[0007] Furthermore, the futon described in Patent Document 2 has a structure in which multiple layers of hard cotton, which has been compressed and thinned by needle punching, are stacked together. Because there are multiple compressed cotton materials, the weight becomes quite heavy, which creates the problem of being inconvenient to handle.

[0008] Therefore, the present invention aims to provide a three-layer or five-layer mattress futon that does not have machine stitching that penetrates the cover material, in order to simplify the comfort sewing process. [Means for solving the problem]

[0009] To solve the above-mentioned technical problems, the three-layer or five-layer mattress futon of the present invention comprises a core made of a rectangular single sheet, a roll of cotton that completely encloses the core, and a bag-shaped cover material into which the core wrapped in the roll of cotton is inserted through an opening on one side and the opening is sewn shut, wherein the roll of cotton is compressed while being stored in the cover material, and the cover material receives tension from the elastic force of the core and the roll of cotton to maintain the position of the stored roll of cotton and the core.

[0010] According to a preferred embodiment of the present invention, the above-described three-layer or five-layer mattress futon may be made without any stitching that penetrates the cover material, in which case the core and the cotton filling may not have any stitching that penetrates the cover material. For example, the core may be made of a hardened polyester sheet having a thickness of 2 cm to 12 cm, synthesized by heat treatment from a blend of non-recycled polyester cotton and recycled polyester cotton. The cover material may also have a quilted structure in which cotton material is sewn between an outer fabric and an inner fabric. When it has a quilted structure, it becomes a five-layer type, and when the cover material is only fabric without a quilted structure, it becomes a three-layer type.

[0011] Furthermore, the present invention provides a method for manufacturing a three-layer or five-layer mattress futon, comprising wrapping a core made of a rectangular single sheet with cotton batting and inserting it into a bag-shaped cover material, wherein the cover material is held in a holder so that the opening of the cover material is open, the core is placed on a sheet of cotton batting sized to completely enclose the core, the core is wrapped with cotton batting, the core wrapped with cotton batting is inserted together with the cotton batting into the opening of the cover material held in the holder, thereby arranging the core wrapped with cotton batting inside the cover material, and the opening of the cover material is sewn shut.

[0012] According to a preferred embodiment of the present invention, the above-described method for manufacturing a three-layer or five-layer mattress futon can be configured such that the holder has a tubular portion through which the core wrapped in the cover material and the cotton batting passes, and the cotton batting and the core are compressed as they pass through the tubular portion. Furthermore, in the manufacturing process, the cover material may be held in an inverted position around the outer circumference of the tubular portion. [Brief explanation of the drawing]

[0013] [Figure 1] This is a perspective view showing a partially cut example of a three-layer or five-layer mattress futon of the present invention. [Figure 2]Figure 1 shows a cross-sectional view of a process for manufacturing an example of a three-layer or five-layer mattress futon, where (a) is a cross-sectional view of the five-layer mattress futon before it is stored in the cover material, and (b) is a cross-sectional view after it has been stored in the cover material. [Figure 3] This is a schematic cross-sectional view illustrating an example of a manufacturing method for the three-layer or five-layer mattress futon of the present invention, showing the cover material set in the holder. [Figure 4] This is a schematic cross-sectional view illustrating an example of a manufacturing method for the three-layer or five-layer mattress futon of the present invention, showing the cotton batting being placed on a conveyor belt. [Figure 5] This is a schematic cross-sectional diagram illustrating an example of a manufacturing method for the three-layer or five-layer mattress futon of the present invention, showing a point where the core is placed on top of the rolled cotton. [Figure 6] This is a schematic cross-sectional diagram illustrating an example of a manufacturing method for the three-layer or five-layer mattress futon of the present invention, showing the core being wrapped in cotton batting. [Figure 7] This is a schematic cross-sectional view illustrating an example of a manufacturing method for the three-layer or five-layer mattress futon of the present invention, showing the process of inserting the cotton batting and core into the cover material. [Figure 8] This is a schematic cross-sectional view illustrating an example of a manufacturing method for the three-layer or five-layer mattress futon of the present invention, showing the point where the cotton batting and core have been sufficiently inserted into the cover material. [Figure 9] This is a cross-sectional view of a process for manufacturing another example of a three-layer or five-layer mattress futon, where (a) is a cross-sectional view showing the three-layer mattress futon before being stored in the cover material, and (b) is a cross-sectional view after being stored in the cover material. [Figure 10] This is a perspective view showing another example of the three-layer or five-layer mattress futon of the present invention, partially cut away. [Figure 11] This is a perspective view showing another example of the three-layer or five-layer mattress futon of the present invention, partially cut away. [Modes for carrying out the invention]

[0014] Hereinafter, embodiments will be described with reference to the drawings. FIG. 1 is a perspective view showing a futon as a first embodiment with a partial break. The three-layer or five-layer mattress futon 10 of the present embodiment has a structure in which a bag-shaped cover material 20 is formed by a surface fabric 12 on the front side and a back fabric 13 on the back side, and has a core 16 and winding wools 14 and 18 that wrap the core therein.

[0015] The core 16 of the three-layer or five-layer mattress futon 10 of the present embodiment is made of a cured polyester sheet synthesized by heat treatment by blending non-recycled polyester wool and recycled polyester wool, and has a structure made of a plate-shaped cured polyester sheet having a thickness of, for example, 2 cm to 12 cm, more preferably 2.5 cm to 6 cm. The core 16 functions as a relatively firm solid wool layer, and the plate-shaped size can be slightly smaller than the general outer shape of 140 cm × 205 cm considering the amount of winding wool as a futon, and other sizes, for example, the outer shape can also have sizes such as 160 cm × 205 cm, 180 cm × 205 cm, 200 cm × 205 cm, 240 cm × 205 cm, 280 cm × 205 cm, 300 cm × 205 cm.

[0016] For the core 16, a plate-shaped hardened polyester sheet, it is desirable to use a sheet material that is relatively firm and highly elastic. As an example of its manufacturing method, a sheet-shaped polyester cotton sheet is produced by uniformly mixing ordinary polyester cotton, including recycled polyester cotton processed from recycled resources such as PET bottles, with low-melting-point polyester cotton. This sheet is folded over and fed little by little, and multiple polyester cotton sheets are heat-pressed together. Specifically, pressure is applied using a hot roller or the like to press the fibers into a plate shape, and at this time, the temperature is maintained so that the low-melting-point polyester melts and reaches every corner of the sheet. Due to this heating, the polyester cotton sheet is transported through the heat treatment device while the low-melting-point polyester components within the sheet are melted by heat pressing, and cooling air is applied from a blower located at the end of the heat treatment device to harden the molten low-melting-point polyester components. The compressed polyester cotton sheet hardens into a hard state, and the volume of the sheet material is reduced as it hardens.

[0017] The cured polyester sheet used in the core 16 can create a state where the polyester fiber that temporarily melts during heat treatment and the polyester fiber that does not melt are mixed together, especially by mixing low-melting-point polyester fiber. From this state, through a cooling process in an extremely short time, the low-melting-point polyester fiber can be instantaneously solidified to obtain a cured polyester sheet that is overall hard and has a high coefficient of restitution. For example, the low-melting-point polyester fiber has a weight ratio of 10 to 80%, and normal polyester fiber including recycled polyester fiber is uniformly mixed at a weight ratio of 20 to 90% to obtain a polyester fiber sheet. A more preferable weight ratio is, for example, that the low-melting-point polyester fiber has a weight ratio of 20% to 60%, and an even more preferable low-melting-point polyester fiber can have a weight ratio of 25% to 45%. As the low-melting-point polyester fiber, those in which polyester fibers with an overall low melting point are made into a fibrous form can also be used, and fibers with a different composition such as a core-sheath type where the core is made of polyester fiber and the sheath part is made of copolymerized polyester or polyethylene can also be used. As the normal polyester fiber, those with a thickness of, for example, 12 to 18 denier are used, and as the low-melting-point polyester fiber, fibers with a thickness of, for example, 4 to 6 denier can be used. In addition, the core 16 can also be configured using urethane foam or the like.

[0018] The winding fibers 14 and 18 are made of a sheet material such as polyester fiber arranged to wrap the rectangular single-plate core 16. For example, one polyester fiber sheet can be folded approximately in half and arranged so that the core 16 is located at the center, and the core 16 can be held by the winding fibers 14 and 18. The cotton batting 14 and 18 are constructed from materials that are softer and more breathable than the core 16. For example, a blended polyester cotton made by combining virgin polyester cotton with recycled polyester cotton is used. However, to achieve softness, a hollow conjugate type of virgin polyester cotton with cavities inside the fibers can also be used. The blend of virgin polyester cotton and recycled polyester cotton can be, for example, 50:50, but blends such as 40:60 or 60:40 can also be adopted. Although the cotton batting 14 and 18 are softer than the core 16, when they sufficiently enclose the core 16, they can maintain the position of the core 16 within the cotton batting 14 and 18. Furthermore, since the cotton batting 14 and 18 are made from the same type of polyester cotton as the core 16, they also exhibit high adhesion due to their affinity for each other.

[0019] The thickness of the cotton batting 14 and 18 is, for example, about 2 to 4 cm. The thickness when left naturally without any load (see Figure 2(a)) differs from the thickness when stored in the bag-shaped cover material 20 (see Figure 2(b)). In other words, in the three-layer or five-layer mattress futon of this embodiment, the size of the internal space created by the bag-shaped cover material 20 is smaller than the size of the cotton batting 14 and 18 when they are wrapped around the core 16. As a result, the cotton batting 14 and 18 are compressed while being stored in the bag-shaped cover material 20. Consequently, the bag-shaped cover material 20 receives tension from the elastic force of the core 16 and the cotton batting 14 and 18 as a whole, and can maintain the position of the stored cotton batting 14 and 18 and the core 16.

[0020] In the three-layer or five-layer mattress futon 10 of this embodiment, a bag-shaped cover material 20 is used as the bag that encloses the cotton structure, consisting of an outer fabric 12 on the surface side and a lining fabric 13 on the back side. The three sides of the rectangle formed by sewing the outer fabric 12 and lining fabric 13 together create a bag shape, and the cotton structure is placed inside the cover material 20 through the opening on one side. After the cotton structure is placed inside, the opening on one side is sewn shut with thread 22, thereby housing the cotton structure inside the cover material. Furthermore, in the three-layer or five-layer mattress futon 10 of this embodiment, no hem portion with a raised edge is formed on the outer periphery of the cover material. The bag-shaped cover material formed by sewing the outer fabric 12 and lining fabric 20 together is prepared in a size that has a relatively small margin from the size of the board-shaped core 16 that will be placed inside, and the futon is completed by sewing one side shut as if closing a bag after the core 16 and the rolled cotton 14, 18 have been placed inside. The margin from the size of the hardened polyester sheet that forms the core 16 is such that the flat size of the hardened polyester sheet plus the thickness of the sheet is considered to be the size of the sheet when there is no margin, but the margin is approximately 1 to 4 cm larger than that. The rolled cotton 14 and 18 are compressed and inserted into this small margin to create a three-layer or five-layer mattress futon 10. The cover material 20 may have a quilted structure in which cotton material is sewn between the outer fabric and the inner fabric. When it has a quilted structure, it becomes a five-layer type, and when the cover material is just fabric without a quilted structure, it becomes a three-layer type. The cotton material placed between the outer fabric and the inner fabric can be, for example, about 0.3 cm to 1 cm thick, and a relatively thin material has the advantage of being easier to set in the holder.

[0021] Here, the manufacturing method of the three-layer or five-layer mattress futon according to this embodiment will be described with reference to Figures 3 to 8. When manufacturing the three-layer or five-layer mattress futon, as shown in Figure 3, the cover material 62 is first set in the holder 60. The holder 60 is a cylindrical member having an opening 63 corresponding to the width of the futon, and holds the cover material 62 gathered together along the outside of its cylindrical part. The cover material 62 is the outermost part of the three-layer or five-layer mattress futon, and is a bag-shaped fabric member with three sides of a rectangle closed. In the case of the five-layer type, the cover material 62 has a quilted structure. When setting the cover material 62 in the holder 60, it is set, for example, upside down, and the opening 65, which is the opening end of the bag-shaped cover material 62, remains open as it is held in the holder 60. A conveyor 64, which is made up of wooden boards extended in the width direction arranged along a rotating belt, is installed in front of the holder 60, and in the subsequent process, the rolled cotton 66 and the core 68 are stacked on the conveyor 64. The cover material 62 may be a single piece of cloth, or, as in this embodiment, it may have a quilted structure in which a relatively thin cotton material 26 is sandwiched between an outer cloth 24 and an inner cloth 28 and sewn together to create many sections.

[0022] After the cover material 62 is folded and gathered around the outer circumference of the holder 60, a sheet of cotton batting 66 is first placed on the stationary conveyor belt 64, as shown in Figure 4. The size of the cotton batting 66 is such that it can completely enclose the core 68 that will be placed next by folding it over, and it has a surface size that is twice the size of the single plate-shaped core 68 plus a margin around it. Also, for example, if the final thickness of the three-layer or five-layer mattress futon is set to about 10 cm, and the core 68 is 5 cm thick, the thickness of the cotton batting 66 will be, for example, about 3 cm when no pressure is applied.

[0023] Once the cotton batting 66 is spread out on the conveyor belt 64, the core 68 is then placed on top of the cotton batting 66, as shown in Figure 5. As explained earlier, the core 68 is a board material made of hard polyester cotton synthesized by heat treatment from a mixture of non-recycled polyester cotton and recycled polyester cotton, and is placed by an operator in a predetermined position on the spread-out cotton batting 66 on the conveyor belt 64.

[0024] After placing the core 68 on the cotton batting 66, the core 68 is completely wrapped in the cotton batting 66, as shown in Figure 6. Specifically, the cotton batting 66 that protrudes from the core 68 is folded back so that the top of the core 68 is also wrapped in the cotton batting 66. As a result, the core 68 is wrapped in the cotton batting 66 in all directions.

[0025] Next, the conveyor 64 is activated to move the core 68 wrapped in cotton batting 66 together with the cotton batting 66, and as shown in Figure 7, the core 68 wrapped in cotton batting 66 is inserted together with the cotton batting 66 into the opening of the cover material 62 held in the holder 60. At this time, the core 68 wrapped in cotton batting 66 moves through the opening 63 of the holder 60 as the conveyor 64 is activated, while wrapping around the cover material 62. As it moves, the core 68 wrapped in cotton batting 66 is subjected to pressure that compresses it in the circumferential direction as it passes through the opening 63 of the holder 60, and from this compression, the cotton batting 66 makes contact with the cover material 62 with elastic force, holding it in place and applying tension to the cover material 62.

[0026] As the core 68 wrapped in cotton batting 66 passes through the opening 63 of the holder 60, the cotton batting 66 and core 68 are fully housed in the bag-shaped cover material 62, as shown in Figure 8, leaving the opening 65 of the cover material 62 on the holder 60 side. This opening 65 of the cover material 62 is the part where one side of the rectangular bag is open, and by sewing the opening 65 of the cover material 62 closed with the cotton batting 66 and core 68 housed inside, the bag can be closed, completing a three-layer or five-layer mattress futon. In the case of a typical futon, so-called comfort stitching is performed to sew the cotton batting and core through the cover material to prevent misalignment between the cotton batting and the core, or between the cotton batting and the cover material. However, in the manufacturing method of the three-layer or five-layer mattress futon of this embodiment, the cover material 62 receives the tension from the elastic force of the core 68 and cotton batting 66 as a whole, and can maintain the position of the housed cotton batting 66 and core 68, thus eliminating the need for comfort stitching.

[0027] Figure 2 is a cross-sectional view of a part of the three-layer or five-layer mattress futon 10 of this embodiment, showing that the layers are stacked in the order of outer fabric 12, cotton batting 14, core 16, cotton batting 18, and backing fabric 13 from top to bottom. The three-layer or five-layer mattress futon 10 of this embodiment has a structure without comfort stitching between the core and cotton batting, which simplifies the manufacturing process and allows for an overall reduction in the selling price. Eliminating comfort stitching raises concerns about misalignment between the cotton batting 14, 18 and the core 16, and between the cotton batting 14, 18 and the inner surfaces of the outer fabric and backing fabric. However, by using a heat-treated polyester cotton sheet for the core 16, it is possible to suppress the occurrence of areas that partially sag and become structurally weaker. Thus, good friction between the core and cotton batting can be maintained, and at the same time, friction between the cotton batting and the inner surfaces of the outer fabric and backing fabric can also be maintained, preventing overall misalignment.

[0028] The inventors of this invention have conducted tests on the high rebound performance of the hardened polyester sheet described above. In the golf ball drop test, a set number of golf balls were dropped from a certain height, 60 cm in this test, onto the surface of the hardened polyester sheet of this embodiment and, as a comparative example, onto the surface of a polyurethane material. The maximum height reached after bouncing off the surface of each sheet was measured. As shown in Table 1 below, the hardened polyester sheet of this embodiment bounced significantly, reaching a maximum height of approximately 33 to 45 cm. In contrast, when a golf ball was dropped onto the polyurethane material as a comparative example, it only bounced to a height of about 6 cm, demonstrating a significant difference in their coefficients of restitution.

[0029] Table 1 JPEG2026101586000002.jpg45170

[0030] Figure 9 is a schematic cross-sectional view of the three-layer mattress futon. The cover material 20 is not a quilted structure, but is made of a cloth 25 made of polyester or other fibers. The thickness of the cotton batting 14 and 18 is, for example, about 2 to 3 cm, and the thickness when left naturally without any load (see Figure 9(a)) is different from the thickness when it is stored in the bag-shaped cover material 20 (see Figure 9(b)). That is, in the three-layer mattress futon of this embodiment, similar to the five-layer mattress futon described earlier, the size of the internal space created by the bag-shaped cover material 20 is smaller than the size of the cotton batting 14 and 18 when they are wrapped around the core 16. As a result, the cotton batting 14 and 18 are compressed while being stored in the bag-shaped cover material 20, and the bag-shaped cover material 20 is subjected to tension from the elastic force of the core 16 and the cotton batting 14 and 18 as a whole, and can maintain the position of the stored cotton batting 14 and 18 and the core 16.

[0031] Figure 10 is a perspective view showing a partially cutaway three-layer or five-layer mattress futon as a second embodiment. In this embodiment, the three-layer or five-layer mattress futon 30 has a bag-shaped cover material formed by the outer fabric 32 on the surface side and the inner fabric 40 on the back side, and has a core 36 and wrapped cotton 34, 38 inside. In the three-layer or five-layer mattress futon 30 of the second embodiment, a hem portion 42 with a raised edge is formed on the outer periphery of the cover material, but there is no comfort stitching to the core 36 and wrapped cotton 34, 38, which simplifies the manufacturing process and allows for a lower overall selling price.

[0032] Similar to the three-layer or five-layer mattress futon 10 of the first embodiment, the core 36 of the three-layer or five-layer mattress futon 30 of this embodiment is formed using a hardened polyester sheet that is generally hard and has a high coefficient of restitution. As a method for manufacturing this hardened polyester sheet, non-recycled polyester cotton and recycled polyester cotton are blended and mixed with low-melting-point polyester cotton to create a state in which temporarily melted polyester cotton and non-melting polyester cotton are mixed during heat treatment. From there, a cooling treatment is performed for an extremely short time to instantly solidify the low-melting-point polyester cotton, thereby using a hardened polyester sheet that is generally hard and has a high coefficient of restitution.

[0033] The cotton batting 34 and 38 are made of a material such as polyester cotton and are arranged to enclose the core 36. The upper and lower cotton batting 34 and 38 can be arranged to be continuous above and below the core 36, or the core 36 can be sandwiched between the independent cotton batting 34 and 38. As a bag that encloses such a cotton structure, the three-layer or five-layer mattress futon 30 of this embodiment has a bag-shaped cover material formed by the outer fabric 32 on the surface side and the inner fabric 30 on the back side. The three sides of the rectangle formed by the outer fabric 32 and inner fabric 40 are sewn together to form a bag, the cotton structure is stored in the cover material from one of the opening sides, and the opening side is sewn shut with thread after the cotton structure is stored, thereby housing the cotton structure inside the cover material.

[0034] In the three-layer or five-layer mattress futon 30 of this embodiment, there is concern that the internal core and cotton filling may shift due to the elimination of comfort stitching. However, by using a heat-treated sheet of relatively hard polyester cotton for the core 36, it is possible to suppress the occurrence of areas that partially sag and become structurally weak. Thus, good friction can be maintained between the core and the cotton filling, and at the same time, friction can be maintained between the cotton filling and the inner surfaces of the outer and inner fabrics, thereby preventing overall shifting.

[0035] Figure 11 is a perspective view showing a three-layer or five-layer mattress futon as a third embodiment, partially cut away. In this embodiment, the three-layer or five-layer mattress futon 50 has a bag-shaped cover material formed by an outer fabric 52 on the surface side and a backing fabric 48 on the back side, with a core 56 inside and cotton batting 54, 58 surrounding the core. The outer fabric 52 on the surface side and the backing fabric 48 on the back side each have a quilted structure, and cotton batting 49 is present in rectangular or diamond-shaped areas where seams 44 intersect. In the three-layer or five-layer mattress futon 50 of the third embodiment, a hem portion 46 with a raised edge is formed on the outer periphery of the cover material, but there is no comfort stitching between the core 56 and the cotton batting 54, 58, which simplifies the manufacturing process and allows for a lower overall selling price.

[0036] Similar to the three-layer or five-layer mattress futon 10 of the first embodiment, the core 56 of the three-layer or five-layer mattress futon 50 of this embodiment is formed using a hardened polyester sheet that is generally hard and has a high coefficient of restitution. As a method for manufacturing this hardened polyester sheet, non-recycled polyester cotton and recycled polyester cotton are blended and mixed with low-melting-point polyester cotton to create a state in which temporarily melted polyester cotton and non-melting polyester cotton are mixed during heat treatment. From there, a cooling treatment is performed for an extremely short time to instantly solidify the low-melting-point polyester cotton, thereby using a hardened polyester sheet that is generally hard and has a high coefficient of restitution.

[0037] In the three-layer or five-layer mattress futon 50 of this embodiment, the cotton batting 54 and 58 are made of a material such as polyester cotton and are arranged to enclose the core 56. The upper and lower cotton batting 54 and 58 can be arranged to be continuous above and below the core 56, or the core 56 can be sandwiched between the independent cotton batting 54 and 58. As a bag that encloses such a cotton structure, the three-layer or five-layer mattress futon 50 of this embodiment has a bag-shaped cover material formed by a quilted outer fabric 52 on the surface side and a lining fabric 48 on the back side. These outer fabric 52 and lining fabric 48 are sewn together along three sides of a rectangle to form a bag shape, the cotton structure is stored in the cover material from one open side, and the open side is sewn shut with thread after the cotton structure is stored, thereby housing the cotton structure inside the cover material.

[0038] In the three-layer or five-layer mattress futon 50 of this embodiment, there is concern that the internal core and cotton filling may shift due to the elimination of comfort stitching. However, by using a heat-treated sheet of relatively hard polyester cotton for the core 56, it is possible to suppress the occurrence of areas that partially sag and become structurally weak. Thus, the friction between the core and the cotton filling can be maintained well, and at the same time, the friction between the cotton filling and the inner surfaces of the outer and inner fabrics can also be maintained, thereby preventing overall shifting. [Explanation of Symbols]

[0039] 10, 30, 50 Three-layer or five-layer mattress futon 12, 32, 52 Outer fabric 14, 34, 54 rolls of cotton 16, 36, 56 center core 18, 38, 58 rolled cotton 13, 40, 48 Lining 20 Cover material 22 threads 24 Outer cloth 25 Cloth 26 Cotton material 28 Inner cloth 44 stitches 42, 46 Hem 49 Cotton 60 holder 62 Cover material 63 Opening 64 Conveyor 65 Opening 66 rolls of cotton 68 Core

Claims

1. It comprises a core made of a rectangular single sheet, a cotton batting that completely encloses the core, and a bag-shaped cover material into which the core wrapped in the cotton batting is inserted through an opening on one side and the opening is sewn shut. A three-layer or five-layer mattress futon characterized in that the rolled cotton is compressed and stored in the cover material, and the cover material receives overall tension due to the elastic force of the core and the rolled cotton, thereby maintaining the position of the stored rolled cotton and the core.

2. A three-layer or five-layer mattress futon according to claim 1, characterized in that the core is made of a hardened polyester sheet having a thickness of 2 cm to 12 cm, synthesized by heat treatment from a blend of non-recycled polyester cotton and recycled polyester cotton.

3. A three-layer or five-layer mattress futon according to claim 1, characterized in that the cover material has a quilted structure in which cotton material is sewn together with an outer fabric and an inner fabric.

4. A method for manufacturing a three-layer or five-layer mattress futon, comprising wrapping a core made of rectangular veneers with cotton batting and inserting it into a bag-shaped cover material, The cover material is held in the holder so that the opening of the cover material is open. The core is placed on the sheet-like cotton roll that is sized to completely enclose the core. The core is wrapped in the cotton batting, The core wrapped in the cotton is inserted together with the cotton into the opening of the cover material held in the holder, thereby placing the core wrapped in the cotton inside the cover material. A method for manufacturing a three-layer or five-layer mattress futon, characterized by sewing the opening of the cover material.

5. A method for manufacturing a three-layer or five-layer mattress futon according to claim 4, wherein the holder has a cylindrical portion through which the core wrapped in the cover material and the cotton batting passes, and the cotton batting and the core are compressed as they pass through the cylindrical portion.

6. A method for manufacturing a three-layer or five-layer mattress futon according to claim 5, characterized in that the cover material is held in an inverted state on the outer circumference of the cylindrical part.

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