Mattress, manufacturing method, and disposal method

Abstract

A mattress with pocket springs is provided, comprising a coil spring forming the pocket spring, a first fabric for forming a pocket space for receiving the coil spring, and a second fabric extending in a planar shape to cover the entire pocket space. Each row of pocket spaces has one first fabric. The first fabric has continuous stitches along a first direction on both sides of the center of the plurality of pocket spaces. The second fabric is fixed in a portion located between two stitches of the first fabric and also between two stitches in a second direction intersecting the first direction. The stitches are formed in such a way that they break when this portion of the first fabric is pulled in a direction away from the pocket space.

Description

Technical Field

[0001] This disclosure relates to a mattress, a method of manufacturing it, and a method of disposal. Background Technology

[0002] Mattresses with pocket springs are already available, which house the coiled springs within a pocket-shaped body forming the pocket space. It is also known that in such mattresses, the sides of the pockets for each coiled spring are joined together, stitching is formed along the circumference of each pocket, and the top of the pocket is glued to the underside of a mounting unit using an adhesive (see, for example, Patent Document 1). According to this technique, by pulling the mounting unit upwards, the stitching of the pockets breaks, opening the top of each pocket and allowing easy removal of the coiled spring.

[0003] <Prior art documents>

[0004] <Patent Documents>

[0005] Patent Document 1: Japanese Patent Application Publication No. 2012-95785 Summary of the Invention

[0006] <Problem to be solved by this invention>

[0007] However, according to the existing technology described above, a single sheet of fabric needs to be cut to form a pocket for each coil spring, thus increasing manufacturing costs. Furthermore, since the pockets are formed separately, assembly errors are prone to occur when multiple pockets are arranged. These assembly errors can cause some pockets to fail to break at the seams, affecting the overall structure and potentially preventing the desired simultaneous breakage of all seams.

[0008] On the other hand, if multiple bag spaces are formed without cutting a single piece of fabric, it may solve some of the problems mentioned above when forming separate bag-like structures. However, since multiple bag spaces are connected to each other by fabric, it is difficult to form a seam that can easily open multiple bag spaces.

[0009] The purpose of this disclosure is to create multiple pocket spaces in a mattress without cutting a single sheet of fabric, and to create seams on the fabric that allow the multiple pocket spaces to open easily.

[0010] <Methods for solving problems>

[0011] One aspect of the invention provides a mattress with pocket springs, comprising: a coil spring forming the pocket spring; a first fabric forming a pocket space for receiving the coil spring; and a second fabric extending in a planar shape to cover the entirety of the pocket space. One sheet of the first fabric is arranged in each column of the pocket spaces, the first fabric having continuous stitches along a first direction on both sides relative to the center of the plurality of pocket spaces. The second fabric is fixed to a portion of the first fabric between two of the stitches and between two of the stitches in a second direction intersecting the first direction, the stitches being configured such that pulling the portion of the first fabric away from the pocket space would cause the stitches to break.

[0012] <The Effects of the Invention>

[0013] According to this disclosure, multiple pocket spaces can be formed in a mattress without cutting a single sheet of fabric, and stitching can be formed on the fabric to easily open the multiple pocket spaces. Attached Figure Description

[0014] Figure 1 It is a perspective view showing the mattress in use.

[0015] Figure 2 This is an explanatory diagram of the cross-sectional structure of the mattress in Example 1, and a schematic diagram of the cross-sectional structure of the mattress.

[0016] Figure 2A This is a schematic cross-sectional view of a mattress according to another embodiment.

[0017] Figure 3 It is a diagram that roughly shows the arrangement of the coils in the spring coils when viewed from above.

[0018] Figure 4A This is an illustration of a nonwoven fabric used to form bag spaces that individually house the coiled springs.

[0019] Figure 4B This is an illustration of a nonwoven fabric used to form bag spaces that individually house the coiled springs.

[0020] Figure 4C This is an illustration of a roll of nonwoven fabric.

[0021] Figure 5 It is a plan view of nonwoven fabric used to form bag spaces that individually accommodate multiple coiled springs in a row.

[0022] Figure 6 This is an explanatory diagram of the method for forming a bag space from nonwoven fabric in Example 1.

[0023] Figure 7This is a side view of Example 1 when three bag spaces are extracted from a row of multiple bag spaces, viewed from the Y direction.

[0024] Figure 8 This is a side view of the X method when three bag spaces are extracted from multiple bag spaces in a column.

[0025] Figure 9 It is along Figure 7 A rough cross-section of line AA.

[0026] Figure 10 It is along Figure 7 A rough cross-sectional view of line BB.

[0027] Figure 11 This is an illustration of the disposal method, and it is a perspective view showing the state of the upper opening of the bag space.

[0028] Figure 12 This is an explanatory diagram of the cross-sectional structure of mattress 20B in Example 2, and a schematic diagram of the cross-sectional structure of the mattress.

[0029] Figure 13 This is a side view taken from the Y direction when three pocket spaces are removed from a row of pocket spaces in Example 2 of the mattress.

[0030] Figure 14 This is a side view taken from the X direction when three pocket spaces are removed from a row of pocket spaces in Example 2 of the mattress.

[0031] Figure 15 This is an oblique view of the bagged spring layer viewed from below.

[0032] Figure 16 This is an explanatory diagram of the kerf configuration.

[0033] Figure 17 This is an explanatory diagram (1) of the mattress disposal method in Example 2.

[0034] Figure 18 This is an explanatory diagram (of 2) of the mattress disposal method in Example 2. Detailed Implementation

[0035] Hereinafter, various embodiments will be described in detail with reference to the accompanying drawings. The scale of the drawings is merely an example and is not intended to be limiting; furthermore, for ease of explanation, shapes and other details within the drawings may sometimes be exaggerated. In this specification, when a nonwoven fabric or similar material is referred to as a single sheet, it means a single sheet (piece) in its product state; multi-layered structures with integrated interlayers are also included in this concept.

[0036] Figure 1This is a perspective view showing the mattress 20 in use. Figure 1 In this diagram, the X, Y, and Z axes are defined as shown in the coordinate system on the right. In the following description, the vertical direction (Z-direction) is based on the usage state of the mattress 20. The mattress 20 is a piece of bedding and is used on the bed frame 7. Furthermore, the mattress 20 can be vertically adjusted, but unless otherwise specified, the upper and lower sides of the mattress 20 will be defined as follows: Figure 1 The shown state is used as a baseline. Additionally, if the mattress cannot be adjusted vertically (for example, refer to...), Figure 2A For mattresses (20A), in order to clearly indicate the top side to the user, markings or other markings can be added to the side of the mattress.

[0037] Figure 2 This is an explanatory diagram of the cross-sectional structure of mattress 20, and a schematic diagram of the cross-sectional structure of mattress 20. Figure 3 It is a diagram that shows the arrangement of coil springs 223a and 223b in the coil layer 223 from a top view. Figure 3 China adopts and Figure 1 The same definition applies to the X direction (an example of the first direction) and the Y direction (an example of the second direction). Here, the long side of the mattress 20 corresponds to the X direction.

[0038] exist Figure 2 In the example shown, the mattress 20 is composed of a quilted portion 21 (hereinafter also referred to as "upper quilted portion 21" for distinction), a filling portion 22, and a quilted portion 23 (hereinafter also referred to as "lower quilted portion 23" for distinction).

[0039] The upper quilted section 21, starting from the top, is composed of a surface material 211, artificial cotton 212, soft polyurethane 213, and non-woven fabric 214. Furthermore, the structure of the upper quilted section 21 is not limited to this; other materials may be added, or some materials may be omitted.

[0040] Surface material 211 can be, for example, a knitted material with antibacterial, deodorizing, and anti-mite functions. Preferably, surface material 211 has a density of 180 g / m³. 2 The above. Surface material 211, for example, can have a thickness of 1 mm.

[0041] Artificial cotton 212, for example, has a density of approximately 140 g / m³. 2 Additionally, artificial cotton 212, for example, can be 10mm thick.

[0042] The density of the flexible polyurethane 213 can be, for example, D28. Additionally, the thickness of the flexible polyurethane 213 can be, for example, 15 mm.

[0043] Nonwoven fabric 214, for example, its density can be approximately 40 g / m³. 2Additionally, the thickness of nonwoven fabric 214 can be, for example, 0.25 mm.

[0044] The filling part 22, from the top, is composed of non-woven fabric 220, soft polyurethane 221, non-woven fabric 222, spring coil layer 223, non-woven fabric 224, soft polyurethane 225 and non-woven fabric 226.

[0045] Nonwoven fabric 220, for example, its density can be approximately 40 g / m³. 2 Additionally, the thickness of the nonwoven fabric 220 can be, for example, 0.25 mm.

[0046] The soft polyurethane 221 may have a density of D21, for example. Additionally, the soft polyurethane 221 may have a thickness of 20 mm, for example. The upper side of the soft polyurethane 221 may be formed with an uneven surface. This improves the volume pressure dispersion value.

[0047] Nonwoven fabric 222, for example, its density can be approximately 80 g / m³. 2 Additionally, the thickness of the nonwoven fabric 222 can be, for example, 0.25 mm.

[0048] In the spring coil layer 223, multiple coil springs 223a and 223b, each forming a pocket spring, are arranged in a parallel configuration. Each row of coil springs 223a and 223b extends along the long side (X direction) of the mattress 20 and connects to each other along the short side (Y direction) of the mattress 20. The number of coil springs 223a and 223b in each row can be the same. Furthermore, in a variation, the multiple coil springs 223a can be arranged in an alternating configuration.

[0049] In this embodiment, as an example, such as Figure 3 As shown, when the columns are arranged from top to bottom in the short side direction (Y direction) as columns 1 to 7, columns 3 to 5 are composed of multiple coil springs 223a, while in other examples they are composed of multiple coil springs 223b. As described above, by utilizing two types of coil springs 223a and 223b, sleep comfort can be effectively improved. Furthermore, in modified examples, one or more types of coil springs can also be used.

[0050] The wire diameter (steel wire diameter) of the coil spring 223a forming the spring coil layer 223 is 1.8 mm, and the coil diameter is 62 mm. Furthermore, the coil spring 223a forming the spring coil layer 223 has 5 turns, and the coil height is 170 mm in its free length and 100 mm after packaging. Each coil spring 223a can be, for example, lantern-shaped.

[0051] Furthermore, the wire diameter (steel wire diameter) of the coil spring 223b forming the spring coil layer 223 is 2.2 mm, and the coil diameter is 62 mm. Additionally, the number of turns of the coil spring 223b forming the spring coil layer 223 is 5.5 turns, and the coil height is 140 mm in its free length and 100 mm when packaged. Each coil spring 223b can be, for example, lantern-shaped.

[0052] Nonwoven fabric 224, for example, its density can be approximately 80 g / m³. 2 Additionally, the thickness of nonwoven fabric 224 can be, for example, 0.25 mm.

[0053] The density of the flexible polyurethane 225 can be, for example, D21. Additionally, the thickness of the flexible polyurethane 225 can be, for example, 15 mm.

[0054] Nonwoven fabric 226, for example, its density can be approximately 40 g / m³. 2 Additionally, the thickness of nonwoven fabric 226 can be, for example, 0.25 mm.

[0055] The lower quilted section 23, starting from the top, is composed of non-woven fabric 231, soft polyurethane 232, artificial cotton 233, and surface material 234. However, the structure of the lower quilted section 23 is not limited to this; other materials may be added, or some materials may be omitted.

[0056] Nonwoven fabric 231, for example, its density can be approximately 40 g / m³. 2 Additionally, the thickness of nonwoven fabric 231 can be, for example, 0.25 mm.

[0057] Soft polyurethane 232, for example, may have a density of D28. Additionally, soft polyurethane 232 may have a thickness of 15 mm.

[0058] Artificial cotton 233, for example, its density can be approximately 140 g / m³. 2 Additionally, artificial cotton 233, for example, can be 10mm thick.

[0059] The surface material 234 can be, for example, a knitted material with antibacterial, deodorizing, and anti-mite functions. Preferably, the density of the surface material 234 is 180 g / m³. 2 The above. Surface material 234, for example, can have a thickness of 1 mm.

[0060] in addition, Figure 2 The image shows a mattress 20 with a specific structure, but the mattress 20 can have any structure as long as it has a coiled spring layer 223 and the coiled spring layer 223 has the following structure. For example, it can have the following structure: Figure 2AThe mattress 20A has the structure shown. In this case, needle-punched cotton 232A is used instead of soft polyurethane 232. This type of mattress 20A is suitable for use in situations where the top and bottom cannot be changed (i.e., the Z-direction positive side is always the top side).

[0061] The following is for reference Figure 4A The following figures illustrate the details of the spring coil 223. Furthermore, in the following description, the structure of the column of coil spring 223a will be described as representative, but the column of coil spring 223b is essentially the same.

[0062] Figures 4A to 4C This is an explanatory diagram of the nonwoven fabric 250 (an example of the first fabric) used to form the bag space S1 that respectively accommodates the coil spring 223a.

[0063] Multiple sheets of nonwoven fabric 250 can be formed from the nonwoven fabric membrane 25, which is rectangular when unfolded. For example, the thread 252 of the nonwoven fabric 250, such as... Figure 4A As shown, when laying out the nonwoven fabric membrane 25 that has been rolled into a roll, a thread forming knife 400 can be used. Figure 4A Only one is shown in the diagram. Pin 252, as... Figure 4A As shown, two parallel lines are formed. Here, the thread forming blade 400, for example, has a blade length of about 3 mm, and can be periodically arranged at 1 mm intervals along the circumferential direction. Furthermore, the nonwoven fabric 250 that forms the thread 252 in this way, as... Figure 4C As shown, it can be rolled into a roll for management. In this case, the winding direction of the nonwoven membrane material 25 can correspond to... Figure 3 The X direction is indicated in the figure.

[0064] Or, such as Figure 4B As shown, for a single nonwoven fabric membrane 25 used to form multiple sheets of nonwoven fabric 250, threads 252 can be formed simultaneously during multiple cuts to form the nonwoven fabric 250. This cutting and thread formation can also be achieved when the nonwoven fabric membrane 25, which has been rolled into a roll, is laid out. Therefore, compared to the case where the thread formation is performed separately, the manufacturing process can be completed more efficiently. Here, when the single nonwoven fabric membrane 25 used to form multiple sheets of nonwoven fabric 250 is cut into multiple sheets, this can be achieved by cutting only along the X direction corresponding to the laying direction, and separately cutting along the Y direction (cross-direction cutting). Figure 4B The diagram illustrates, in a pattern, the stitches 252 and cut lines 253 formed on a single nonwoven fabric membrane 25 used to form four nonwoven fabrics 250. In this case, the nonwoven fabric 250, after being cut and having the stitches 252 formed, is as follows: Figure 4C As shown, it can be rolled into a roll for management and transportation.

[0065] Here, as described above, when the length of the nonwoven fabric 25 rolled into a roll after forming the thread 252 is the length of multiple nonwoven fabrics 250, it can be cut along the Y direction into a length of 1 sheet in the X direction to form individual nonwoven fabrics 250 of 1 sheet length.

[0066] Figure 5 It is relative to a column of multiple coiled springs 223a ( Figure 3 There are 11 coiled springs 223a) forming a plan view of a nonwoven fabric 250 that can respectively house bag spaces S1 for these coiled springs. Figure 5 The text refers to the unfolded state of the nonwoven fabric 250 before forming the bag space S1. Figure 5 In the diagram, the single-point chain line L1 represents the center line of the nonwoven fabric 250 in the Y direction, and the shadow lines at the upper and lower ends correspond to the welded portion 258 described later. Figure 6 This is an illustrative diagram illustrating the method of forming bag space S1 using nonwoven fabric 250. Figure 7 This is a side view taken from the Y direction, showing three bag spaces S1 extracted from a column of multiple bag spaces S1. Figure 7 For ease of explanation, the coiled spring 223a within the bag space S1 formed by the nonwoven fabric 250 is shown in a perspective-based pattern. Figure 7 (The following) Figure 8 as well as Figure 9 Similarly, in the diagram, each welded part 256, 258 and adhesive 80, 82, 84 are represented by a shading pattern. Figure 8 This is a side view when the space S1 of three adjacent bags in the Y direction is extracted and viewed along the X direction. Figure 8 For ease of explanation, the coiled spring 223a within the bag space S1 formed by the nonwoven fabric 250 is also shown in a perspective-based pattern. Figure 7 as well as Figure 8 The text also indicates the non-woven fabrics 222 and 224 on the upper and lower sides of the bag space S1. Figure 9 It is along Figure 7 A rough cross-section of line A-A. Figure 10 It is along Figure 7 A schematic cross-sectional view of line BB. Here, Figure 7 For ease of explanation, line BB is slightly off from line 252 in the diagram, but it is actually the line along line 252. Figure 11 This is an explanatory diagram of the disposal method, and it is a perspective view showing the state of the upper opening of the bag space S1.

[0067] Non-woven fabric 250, such as Figure 5As shown, there are two threads 252 parallel to each other along the X direction. In the unfolded state of the nonwoven fabric 250, the distance between the threads 252 in the Y direction is a predetermined interval corresponding to the size of the bag space S1, specifically, it is intentionally made to be larger than the outer diameter (the diameter of the largest part) of the coil spring 223a.

[0068] When forming the coiled spring assemblies (assemblies consisting of nonwoven fabric 250 and coiled spring 223a integrated by welding parts 256 and 258), such as Figure 6 In a schematic representation, all the coil springs 223a constituting a column are positioned with their coil center axes perpendicular to the surface between the threads 252 on a sheet of nonwoven fabric 250. At this time, the positioning of each coil spring 223a relative to the sheet of nonwoven fabric 250 is as follows, with the line segment connecting the coil center axes of each coil spring 223a (refer to...) Figure 6 The single-point chain line L2 is located approximately at the center (center in the Y direction) between the two line feet 252.

[0069] With the nonwoven fabric 250 and multiple coiled springs 223a arranged as described above, by folding the nonwoven fabric 250 back while its two ends in the Y direction are overlapped, the multiple coiled springs 223a can be covered by the nonwoven fabric 250. At this time, two consecutive thread leads 252 in the X direction are located on both sides of the multiple coiled springs 223a in the Y direction.

[0070] Furthermore, since the two ends of the nonwoven fabric 250 in the Y direction are fused together, a welded portion 258 is formed. That is, a row of nonwoven fabrics 250 has a welded portion 258 formed by joining the ends together on the side of each bag space S1 in the Y direction (an example of the second welded portion). In addition, a welded portion 256 is formed in such a way as to separate the bag spaces S1 of each adjacent coil spring 223a in the X direction (an example of the first welded portion). In addition, welded portions 256 can also be formed at both ends of the nonwoven fabric 250 in the X direction. Figure 6 In the example shown, the welded portion 256 of the nonwoven fabric 250 is designated as 256-1 to 256-3. In this case, a welded portion 256 is formed by welding a pair of portions 256-1 together, another welded portion 256 is formed by welding a pair of portions 256-2 together, and yet another welded portion 256 is formed by welding a pair of portions 256-3 together.

[0071] The coiled spring assemblies formed as described above (assemblies consisting of nonwoven fabric 250 and coiled spring 223a integrated by welding portions 256 and 258), such as Figure 8 As shown, the Y-direction sides are joined together by adhesive 80. Additionally, the coil spring assemblies in each column, as... Figure 7 as well as Figure 8 As shown, the nonwoven fabric 222 extending in the XY plane is bonded to the upper side by adhesive 82, and the nonwoven fabric 224 extending in the plane is bonded to the lower side by adhesive 84. Here, the nonwoven fabric 222 is a structure shared by all the coil springs 223a and 223b in the mattress 20, and is bonded (fixed) to the nonwoven fabric 250 forming the pocket spaces S1. By providing such a nonwoven fabric 222, even when a local load (external load) perpendicular to the surface of the mattress 20 is applied between the pocket spaces S1, local sinking (depression between the pocket spaces S1) can be prevented. The same applies to the nonwoven fabric 224.

[0072] According to this embodiment, each row of bags is formed by using one sheet of nonwoven fabric 250 in the manner described above. Therefore, it is not necessary to cut the nonwoven fabric 250 to form each bag space S1, which can greatly improve productivity.

[0073] Furthermore, according to this embodiment, as described above, a row of nonwoven fabrics 250 has continuous stitches 252 along the X direction on both sides of each bag space S1 in the Y direction. Additionally, two stitches 252, as... Figure 10 As shown, they are substantially at approximately the same height, and when viewed from above, they are continuous in the X direction in the form of surrounding each coil spring 223a. Here, the lead 252 is set at a spacing that will not break due to the repulsive force of each coil spring 223a. In this embodiment, as described above, the lead 252 is a structure consisting of holes of approximately 3 mm in length and 1 mm intervals (i.e., a spacing of 4 mm) periodically arranged along the X direction.

[0074] In this embodiment, the nonwoven fabric 222 is adhered to the nonwoven fabric 250 by adhesive 82. Therefore, when the mattress 20 is discarded, if the nonwoven fabric 222 is pulled relative to the spring coils 223 in the direction of peeling from the spring coils 223, a large force (intentionally set to be greater than the repulsive force of each spring 223a) is applied to the stitches 252 of the nonwoven fabric 250. This allows the stitches 252 in each row to break continuously. Thus, by pulling the portion between two stitches 252 in the Y direction of the nonwoven fabric 250 in the upward direction (i.e., away from the pocket space S1), the stitches 252 can be broken. As described above, according to this embodiment, the upper side (higher than the stitches 252) of each pocket space S1 can be easily opened (see reference). Figure 11 The following description of the operation, which involves peeling the nonwoven fabric 222 from the spring coil layer 223 during the disposal of the mattress 20, causing the threads 252 of the nonwoven fabric 250 to break and thus opening the upper side of each bag space S1, may also be referred to as "nonwoven fabric peeling operation".

[0075] Furthermore, according to this embodiment, as described above, in the unfolded state of the nonwoven fabric 250, the distance between the threads 252 in the Y direction is greater than the outer diameter of the coil spring 223a. Therefore, when the coil spring 223a is housed in the bag space S1, as... Figure 7 as well as Figure 8 As shown, the thread lead 252 is formed below the uppermost coil 2231 and above the lowermost coil 2232 of the coil spring 223a, and is positioned slightly upward relative to the center of the coil spring 223a in the axial direction. For example, as... Figure 7 As shown, the distance Δ1 from the top of the bag space S1 to the thread 252 can be in the range of 12mm to 18mm. Therefore, when the thread 252 breaks by pulling the nonwoven fabric 222 in the direction of peeling from the spring coil 223, the possibility of the portion of the nonwoven fabric 250 above the thread 252 being obstructed by the spring coil 223a is reduced. Here, when the thread 252 breaks by pulling the nonwoven fabric 222 in the direction of peeling from the spring coil 223, if the portion of the nonwoven fabric 250 above the thread 252 is obstructed by the spring coil 223a, a portion of the pulling force of the nonwoven fabric 222 is consumed by the spring coil 223a, and correspondingly, the force required to break the thread 252 increases. Therefore, according to this embodiment, the thread 252 can be broken with a smaller force, thereby improving the workability of opening the top of each bag space S1 (i.e., the workability of the nonwoven fabric peeling operation).

[0076] Furthermore, if the thread 252 is located lower than the center of the coil spring 223a in the axial direction, and the thread 252 breaks, the portion of the nonwoven fabric 250 higher than the thread 252, along with the nonwoven fabric 222 itself, may be obstructed by the coil spring 223a. This obstruction will lead to a deterioration in workability. In this respect, according to this embodiment, such inconvenience is less likely to occur, and workability when opening the upper side of each bag space S1 (i.e., the workability of the nonwoven fabric peeling operation) can be improved.

[0077] Furthermore, according to this embodiment, as described above, in the unfolded state of the nonwoven fabric 250, the distance between the threads 252 in the Y direction is greater than the outer diameter of the coil spring 223a. Therefore, with the upper opening of the bag space S1, the coil spring 223a can be easily removed from the upper opening of the bag space S1. That is, the workability of removing the coil spring 223a can also be improved.

[0078] In this embodiment, the welded portion 256, as shown Figure 7As shown, it is preferable to form along the vertical direction and terminate near the front of the thread 252 in the vertical direction. Furthermore, in this embodiment, the weld portion 256 formed along the X direction between the two bag spaces S1 is divided into three sections in the vertical direction; however, there may be more or fewer sections. Additionally, the weld portion 256 formed along the X direction between the two bag spaces S1 may be continuous in the vertical direction.

[0079] In this embodiment, the welded portion 256 separating the bag space S1 in the X direction is positioned lower than the thread 252. Therefore, compared to the case where the thread 252 includes the welded portion 256 (i.e., the thread 252 is welded to form the welded portion 256), the workability when the thread 252 breaks is improved. That is, since the area higher than the thread 252 (the vertical range) is narrower, if the portion higher than the thread 252 is also welded, the thread 252 may weld together in the Y direction. Conversely, since the area lower than the thread 252 (the vertical range) is wider, if welding is only performed in the portion lower than the thread 252, such as… Figure 10 As shown, the possibility of wire leads 252 fusing together in the Y direction is reduced. That is, while ensuring the necessary welding range in the vertical direction, the possibility of wire leads 252 fusing together in the Y direction is reduced. If wire leads 252 fusing together in the Y direction, the force required to cause the wire leads 252 to break continuously would become excessive. Therefore, according to this embodiment, the possibility that the force required to cause the wire leads 252 to break continuously due to the welded portion 256 can be reduced.

[0080] In addition, in this embodiment, pin 252 is as follows Figure 8 As shown in the schematic diagram, the welded portion 258, which joins the ends of the nonwoven fabric 250 in the Y direction, is located higher than this position. Therefore, compared to the case where the thread 252 is included in the welded portion 258 (i.e., the thread 252 is welded to form the welded portion 258), the workability of breaking the thread 252 can be improved. That is, the force required to break it can be appropriately reduced.

[0081] Here, Figure 4A In the accompanying drawings, a single sheet of nonwoven fabric 250 is used in each column of the bag spaces S1 arranged along the X direction; alternatively, a single sheet of nonwoven fabric 250 can also be used in each column of the bag spaces S1 arranged along the Y direction. That is, this structure, as... Figure 4A Description of the accompanying drawings (including) Figure 12 (As illustrated in the accompanying diagrams), the structure can be modified by replacing the X and Y directions with the Y and X directions respectively. In this case, essentially the same effect can be achieved.

[0082] The following is for reference Figure 12 Other embodiments will be described with reference to the accompanying drawings. For ease of explanation, the above-described embodiments will be referred to as "Embodiment 1". Figure 12 The embodiment shown in the accompanying drawings is referred to as "Embodiment 2". In the description of Embodiment 2, the same reference numerals are used for structural elements that are the same as those in Embodiment 1 described above, and their descriptions are sometimes omitted.

[0083] Figure 12 This is an explanatory diagram of the cross-sectional structure of the mattress 20B in this embodiment, and a schematic diagram of the cross-sectional structure of the mattress 20B. Figure 13 This is a side view taken along the Y direction when three pocket spaces S1 are removed from one example of the mattress 20B in this embodiment. Figure 14 This is a side view taken along the X direction when three pocket spaces S1 are removed from a row of multiple pocket spaces S1 in the mattress 20B of this embodiment. Figure 15 This is an oblique view of the part of mattress 20B consisting of non-woven fabric 224B, spring coil layer 223B and non-woven fabric 222 (hereinafter also referred to as "pocket spring layer 2") viewed from below. Figure 16 This is an explanatory diagram of the position of the slit 29 in the X direction relative to the bag space S1 column in the X direction. It shows the lower part that can be seen from above after being cut along the XY plane passing through the center of the axial direction of the coil spring 223a, where the line where the slit 29 is provided is indicated by the dashed line 290.

[0084] The mattress 20B in this embodiment is relative to... Figure 2A The difference in the mattress 20A shown is that the spring coil layer 223 is replaced with a spring coil layer 223B, and the nonwoven fabric 224 is replaced with nonwoven fabric 224B (an example of the second fabric). Furthermore, in this embodiment, the nonwoven fabric peeled from the spring coil layer 223B during the nonwoven fabric peeling operation is nonwoven fabric 224B, which differs from the aforementioned embodiment where the nonwoven fabric peeled from the spring coil layer 223B during the peeling operation is nonwoven fabric 222.

[0085] The spring coil layer 223B of this embodiment differs from the spring coil layer 223 of the above embodiment in the number of bag spaces S1 (and the number of columns of bag spaces S1). Furthermore, this embodiment is suitable for cases where the number of columns (the number of columns arranged in the X direction) of the coil spring 223a is large. The spring coil layer 223B of this embodiment, for example, has 24 columns of bag spaces S1, each column containing 20 bag spaces S1 arranged along the X direction.

[0086] Furthermore, in this embodiment, compared to the spring coil layer 223 of the above embodiment, the thread 252 of the spring coil layer 223B is formed below the uppermost coil 2231 and above the lowermost coil 2232 of the spring coil 223a, and is positioned slightly downward relative to the center of the spring coil 223a in the axial direction. In other words, the structure of the nonwoven fabric 250 in this embodiment is reversed compared to the spring coil layer 223 of the above embodiment.

[0087] The nonwoven fabric 224B of this embodiment differs from the nonwoven fabric 224 of Embodiment 1 in that it has a slit 29 along the X direction, which is the same as the extension direction of the thread 252.

[0088] The slit 29 is formed in a continuous shape along the X direction. Although the slit 29 can be a thread shape that does not separate the nonwoven fabric 224B in the Y direction, it is preferable to be a continuous cut shape that separates the nonwoven fabric 224B in the Y direction. In this embodiment, as a series, the slit 29 is a continuous cut shape.

[0089] The slit 29 improves the workability of the aforementioned nonwoven fabric peeling operation. Specifically, because the nonwoven fabric 224B has the slit 29, it is not necessary to peel the entire fabric at once during the nonwoven fabric peeling operation. That is, the nonwoven fabric 224B can be peeled according to each area (segment) separated by the slit 29. As a result, the peeling force is not excessive, effectively improving the workability of the nonwoven fabric peeling operation. Details regarding this function will be described later. Furthermore, a slit like the slit 29 can also be formed on the nonwoven fabric 222 without it.

[0090] From the perspective of effectively improving the workability of nonwoven fabric peeling operations, such as Figure 15 As shown, the slit 29 preferably extends from one end in the X direction to the other end. That is, the slit 29 can be formed to divide the nonwoven fabric 224B into multiple independent segments in the Y direction. Furthermore, in a modified example, the slit 29 can also be formed to terminate near the end of either side in the X direction. That is, the slit 29 can terminate at the end of one side of the nonwoven fabric 224B in the X direction with a predetermined length of space left. In this case, the slit 29 can terminate at the end of one side of the nonwoven fabric 224B in the X direction at a position closer to one side in the X direction than the bag space S1 closest to that side. Additionally, the predetermined length can be small, for example, less than 20 mm.

[0091] There can be one slit 29, but in this embodiment where there are many columns of bag space S1 in the X direction, it is preferable to provide multiple slits that are separated from each other along the Y direction. That is, the slits 29 are separated from each other in the Y direction, while multiple slits are formed parallel to each other along the X direction. In this case, the spacing between adjacent slits 29 in the Y direction will be greater than the Y-direction length of one column of bag space S1 in the X direction, i.e., the outer diameter (maximum diameter) of the coil spring 223a, and more preferably greater than the Y-direction length of two columns of bag space S1 in the X direction. In addition, the slits 29, when viewed from above, are formed between specific two columns that are adjacent in the Y direction in multiple columns (columns of bag space S1 in the X direction). In this embodiment, as Figure 15 as well as Figure 16 As shown, multiple sets of two specific columns are periodically arranged along the Y direction. That is, slits 29 are formed at approximately equal intervals along the Y direction between the edges 255 on both sides, including the first slit 29 from the edge 255. Specifically, slits 29 are arranged in three columns, forming three columns between two adjacent specific columns. Furthermore, as described later, when the slits 29 are formed after the nonwoven fabric 224B is bonded to the nonwoven fabric 250 by adhesive 84, the spacing of the slits 29 in the Y direction may sometimes not be able to achieve a strictly fixed spacing. Therefore, regarding the Y-direction distance between the slits 29, approximately equal intervals refer to the aforementioned concept that allows for some error.

[0092] Furthermore, in this embodiment, as an example, the nonwoven fabric 224B is substantially divided into 8 separate regions (segments), forming 8 columns in the X direction. In this case, one column of the nonwoven fabric 224B covers the range of 3 columns of the bag space S1 in the X direction.

[0093] The manufacturing method of the mattress 20A in this embodiment can be substantially the same as that of the mattress 20 in Embodiment 1 described above. In this case, the nonwoven fabric 224B (nonwoven fabric in the state without slits 29) can be fixed to the spring coil layer 223B using adhesive 84, and then slits 29 are formed in the nonwoven fabric 224B. In this case, compared to the case where it is necessary to fix the nonwoven fabric 224B, which has been pre-cut by slits 29, to the spring coil layer 223B, productivity can be improved.

[0094] The following is for reference Figure 17 as well as Figure 18 The function of the slit 29 (to improve the workability of the nonwoven fabric peeling operation) and the disposal method of the mattress 20B are explained together.

[0095] Figure 17 as well as Figure 18 This is an illustration of how to dispose of mattress 20B. Figure 17This indicates the initial state S1700 of the disposal method and the execution state S1702 of the operation of peeling off the first nonwoven fabric 224B. Figure 17 This is an oblique view showing the pocket spring layer 2 (composed of nonwoven fabric 224B, spring coil layer 223B and nonwoven fabric 222) in the mattress 20B in the initial state S1700 and the execution state S1702, viewed from below. Figure 18 It means and Figure 17 Similarly, the oblique view shows the execution state S1704 of the peeling operation of the third piece of nonwoven fabric 224B and the state S1706 after peeling off nonwoven fabric 224B, viewed from below.

[0096] In this embodiment, the method for discarding mattress 20B is implemented in substantially the same manner as the method for discarding mattress 20 in the above embodiment. That is, the method for discarding mattress 20B includes peeling nonwoven fabric 224B from the spring coil layer 223B to break the threads 252 of the nonwoven fabric 250, thereby opening the upper side of each pocket space S1 (i.e., nonwoven fabric peeling operation), and removing the coil springs 223a and 223b from the upper side of each opened pocket space S1. These operations can be performed manually, or partially or entirely using a robot.

[0097] According to this embodiment, as Figure 17 as well as Figure 18 As shown, because the nonwoven fabric 224B has a slit 29 in the X direction, the workability of the nonwoven fabric peeling operation can be effectively improved. Specifically, the operator first removes the part (surface material 234A, etc.) from the mattress 20B, which is a waste object, except for the pocket spring layer 2. With only the pocket spring layer 2 remaining, the pocket spring layer 2 is flipped upside down, forming an initial state S1700 where the nonwoven fabric 224B with the pocket spring layer 2 is on the top. Next, from the initial state S1700, the operator peels the nonwoven fabric 224B in the form of pulling the column at the very end upwards using the slit 29 at the end (refer to arrow R170). The operator repeats the above operation for each column of the nonwoven fabric 224B (refer to...). Figure 18 In execution state S1704, the entire column of nonwoven fabric 224B (i.e., the entire nonwoven fabric 224B) is peeled off in state S1706, completing the nonwoven fabric peeling operation. Next, after the operator completes the nonwoven fabric peeling operation, the coil springs 223a and 223b are removed from the bag spaces S1 through the openings that are higher than the thread 252 (upper from the operator's perspective).

[0098] If the bonding strength of the adhesive 84 between the nonwoven fabric 250 and the nonwoven fabric 224B is insufficient, it will be difficult to effectively break the thread 252 during the nonwoven fabric peeling operation. For example, if the adhesive 84 breaks at the bonding point before the thread 252 breaks during the nonwoven fabric peeling operation, the thread 252 cannot break. Therefore, it is necessary to set a high bonding strength of the adhesive 84 between the nonwoven fabric 250 and the nonwoven fabric 224B to ensure that the thread 252 breaks first. However, conversely, if the adhesive 84 is ensured to exert appropriate bonding strength between the nonwoven fabric 250 and the nonwoven fabric 224B, the force required to peel the entire nonwoven fabric 224B simultaneously may become excessive. In addition, if the nonwoven fabric 224B is large, the coating area of ​​the adhesive 84 also increases accordingly, so the force required to peel the entire nonwoven fabric 224B simultaneously may become excessive.

[0099] Therefore, according to this embodiment, instead of peeling the nonwoven fabric 224B as a whole, the nonwoven fabric 224B can be peeled off column by column separated by the slit 29. Thus, the force required for peeling is not excessive, improving the workability of the nonwoven fabric peeling operation.

[0100] Furthermore, the slit 29 in this embodiment is applied to Figure 2 In the case of the mattress 20 shown, the spring coil 223 can be replaced with a spring coil 223B, and the same slit 29 as the slit 29 of the nonwoven fabric 224B can be formed in the nonwoven fabric 222. Alternatively, the same slit 29 can be formed in the nonwoven fabric 224, either in place of the nonwoven fabric 222 or as an addition.

[0101] Furthermore, as described above, the spring coil layer 223B of this embodiment is a structure inverted from the spring coil layer 223 of the above embodiment, meaning that the structure of the nonwoven fabric 250 is reversed. Therefore, as... Figure 14 As shown, the adhesive 80 can be placed only above the thread 252. Placing the adhesive 80 below the thread 252 also deteriorates the workability of the nonwoven fabric peeling operation. That is, if the adhesive 80 is placed below the thread 252, the force applied during the nonwoven fabric peeling operation will be transmitted through the adhesive 80 to the adjacent columns of nonwoven fabric 250 in the Y direction (between the columns of nonwoven fabric 250 separated by the slit 29), thus increasing the force required for the thread 252 to break. Therefore, as... Figure 14 As shown, when the adhesive 80 is placed only above the thread 252, the force of the nonwoven fabric peeling operation will not necessarily spread through the adhesive 80 to the nonwoven fabrics 250 in adjacent columns across the cut 29. Therefore, the force required for peeling is not excessive, improving the workability of the nonwoven fabric peeling operation.

[0102] The embodiments have been described in detail above, but the present invention is not limited to the specific embodiments, and various modifications and alterations are permitted within the scope of the claims. Furthermore, all or more of the structural elements of the above embodiments can be combined.

[0103] For example, in the above embodiment, the thread 252 is formed at a position slightly upward relative to the center in the vertical direction of the coil springs 223a and 223b. Alternatively, or as an addition, the thread 252 can also be formed at a position slightly downward relative to the center in the vertical direction of the coil springs 223a and 223b. In this case, a structure can be achieved where the thread 252 can be easily broken by pulling from the opposite side (i.e., the direction from which the nonwoven fabric 224 is peeled off from the spring coil layer 223). For example, if the mattress 20 is adjustable in height, and the thread 252 is formed at a position slightly upward relative to the center in the vertical direction of the coil springs 223a and 223b, and at a position slightly downward relative to the center in the vertical direction of the coil springs 223a and 223b, respectively, the user does not need to consider the vertical direction of the mattress 20 and can break the upper or lower thread 252 by pulling the nonwoven fabric 222 or nonwoven fabric 224. Alternatively, lead 252 can also be formed near the center of coil springs 223a and 223b in the vertical direction (at a position without deviation in the vertical direction).

[0104] In addition, in reference Figure 12 In Embodiment 2 described above, as illustrated in the accompanying drawings, the slit 29 and the thread 252 are formed only along the X direction, but this is not a limitation. A Y-direction slit (not shown) can also be formed that intersects with the slit 29 formed along the X direction. In this case, the length of the area (segment) separated by the slit on the nonwoven fabric 224B in the X direction is shorter than that of the slit in the Y direction. Therefore, the increased number of areas improves the workability of the nonwoven fabric peeling operation.

[0105] The following notes are provided in connection with the disclosure of Embodiment 1 above.

[0106] [Postscript 1]

[0107] A mattress having a plurality of pocket springs arranged orthogonally along a first direction and a second direction in a plane perpendicular to the vertical direction, comprising: coil springs for forming each pocket spring; a plurality of pocket spaces arranged along the first direction for receiving the plurality of coil springs; a first fabric formed as a single sheet, the first fabric having continuous stitches on both sides of the center of the plurality of pocket spaces in the second direction, the stitches being formed in such a way that they would break when a portion between two of the stitches is pulled in the second direction of the first fabric in an upward or downward direction (away from the pocket space).

[0108] [Postscript 2]

[0109] The mattress as described in Appendix 1 also includes a second fabric that is fixed to the portion of the first fabric.

[0110] [Postscript 3]

[0111] As described in Appendix 2, the mattress is arranged in a manner in which a plurality of pocket spaces are arranged in the first direction to form a plurality of columns in an adjacent configuration in the second direction. In each column, one sheet of the first fabric is used. The second fabric is fixed to the plurality of the first fabrics in the plurality of columns and extends in a plane formed by the first direction and the second direction on the upper or lower side of the plurality of pocket spaces in the plurality of columns.

[0112] [Postscript 4]

[0113] According to Appendix 3, the first fabric of a row has a second welded portion on the side of one side of the second direction of each of the plurality of pocket spaces in the row, where the ends of the first fabric join together, and the stitches are located above or below the second welded portion.

[0114] [Postscript 5]

[0115] According to any one of Appendices 1 to 4, a mattress has a first fabric having a first welded portion that divides the spaces of a plurality of pockets arranged in the first direction, the first welded portion being formed in the vertical direction with the shape terminating near the front of the stitch in the vertical direction.

[0116] [Postscript 6]

[0117] According to any one of the appendices 1 to 5, the mattress is formed at a position lower than the uppermost coil and higher than the lowermost coil, while being offset upward or downward relative to the center of the coil in the axial direction.

[0118] In addition, the following notes are provided regarding the content disclosed in Embodiment 2 above.

[0119] [Postscript 11]

[0120] A mattress having a plurality of pocket springs arranged orthogonally along a first direction and a second direction in a plane perpendicular to the vertical direction, comprising: coil springs forming each pocket spring; a first fabric forming a plurality of pocket spaces for receiving the plurality of coil springs; a second fabric extending planarly to cover the entire plurality of pocket spaces from a first side in the vertical direction and fixed to the first fabric; a plurality of the first fabrics arranged in a row of the plurality of pocket spaces arranged in the first direction, one sheet per row; the plurality of the first fabrics having continuous stitching along the first direction on both sides of the plurality of pocket spaces in the second direction; and the second fabric having slits along the first direction.

[0121] [Postscript 12]

[0122] According to Appendix 11, the slit extends from one end of the second fabric in the first direction to the other end.

[0123] [Postscript 13]

[0124] According to the mattress described in Appendix 11 or 12, the slits are provided in a plurality of forms that are separated from each other in the second direction, and the slits are formed in the plurality of columns in the second direction, between two adjacent specific columns in the second direction.

[0125] [Postscript 14]

[0126] According to the mattress described in Appendix 13, the slits are formed at approximately equal intervals in the second direction.

[0127] [Postscript 15]

[0128] According to Appendix 13 or 14, the mattress has two columns formed in plan view between two adjacent slits in the second direction, or between the edge of the second fabric in the second direction and the slit adjacent to that edge.

[0129] [Postscript 16]

[0130] According to any one of Appendices 11 to 15, a mattress of the first fabric has a first welded portion that divides the plurality of pocket spaces arranged in the first direction, the first welded portion being formed only in the vertical direction on a second side opposite to the first side of the stitching.

[0131] [Postscript 17]

[0132] According to any one of Appendices 11 to 16, in each column of the first fabric, adjacent first fabrics in the second direction are glued to each other on the side in the second direction, and the stitching is located closer to the first side than the glued portion.

[0133] Symbol Explanation

[0134] 7 bed frames

[0135] Mattresses 20, 20A, and 20B

[0136] 21Upper side quilting part

[0137] 22Filling Department

[0138] 23 Lower quilting section

[0139] 25 Non-woven membrane material

[0140] 80 adhesive

[0141] 82 adhesive

[0142] 84 adhesive

[0143] 211 Surface Material

[0144] 212 artificial cotton

[0145] 213 Soft Polyurethane

[0146] 214 nonwoven fabric

[0147] 220 nonwoven fabric

[0148] 221 Soft Polyurethane

[0149] 222 nonwoven fabric

[0150] 223, 223B spring coil

[0151] 223a coil spring

[0152] 223b coil spring

[0153] 224, 224B nonwoven fabric

[0154] 225 Soft Polyurethane

[0155] 226 nonwoven fabric

[0156] 231 nonwoven fabric

[0157] 232 Soft Polyurethane

[0158] 233 Artificial Cotton

[0159] 234 Surface Material

[0160] 250 nonwoven fabric

[0161] 252 pins

[0162] 256 weld section

[0163] 258 Welding Section

[0164] 400 thread forming knife

[0165] 2231 volume line

[0166] 2232 roll line

Claims

1. A mattress with pocket springs, comprising: A coiled spring, forming the pocket spring; The first piece of fabric forms a bag-like space for housing the coiled spring; and The second piece of fabric extends in a planar shape to cover the entire space of the bag. Relative to the columns of the bag space, one sheet of the first fabric is placed in each column. The first fabric has continuous stitching on both sides of the center of the plurality of bag spaces in a first direction. The second fabric is fixed to the portion between the two threads of the first fabric, which is also the portion between the two threads in the second direction that intersects the first direction. The second fabric has a slit along the first direction. The stitching is formed in such a way that it will break when the portion of the first fabric is pulled in a direction away from the bag space.

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

3. The mattress according to claim 1 or 2, wherein, In a second direction intersecting the first direction, a plurality of slits are provided in a manner separate from each other. From a top view, the cuts are formed between specified columns that are adjacent to each other in the second direction.

4. The mattress according to claim 1, wherein, The thread is formed in the vertical direction at a position closer to the second fabric side than the center of the spring's axial direction.

5. A method for manufacturing a mattress according to any one of claims 1 to 3, comprising: The process of fixing the second fabric to the first fabric; and The process of forming the slit in the second fabric that is fixed to the first fabric.

6. A method for manufacturing a mattress according to any one of claims 1 to 3, comprising: A preparation process for preparing the first fabric having the aforementioned stitches; The process of positioning the center of a number of coiled springs contained in a row of the bag space at the center between the stitches along the second direction on the first fabric; and The process of covering the coil spring by overlapping the ends of the first fabric in the second direction with each other.

7. The manufacturing method according to claim 6, wherein, The preparation process includes the process of cutting a piece of fabric used to form multiple pieces of the first fabric into multiple pieces while simultaneously forming the stitches.

8. A method for discarding a mattress according to any one of claims 1 to 3, comprising: The first step involves peeling the second fabric from the first fabric and destroying the first fabric using the stitching. and The second step is to remove the coiled spring from the bag space that opens as the first fabric is broken, following the first step.

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