Glue-free mattress and manufacturing method thereof

Abstract

The invention relates to the technical field of mattresses, and particularly discloses a glue-free mattress and a manufacturing method thereof.The manufacturing method includes the steps that a part A containing springs, a metal frame, a hard foam frame, gridding cloth and thread gluing buckles arranged on the surfaces of the upper gridding cloth and the lower gridding cloth in a threading mode is manufactured; preparing materials according to a specific sequence, and quilting to form a part B; preparing and quilting fabric and related materials for processing the vertical facade of the mattress to form a part C; and finally, processing and connecting the part A and the part C, and sewing the part A and the part B in a surrounding edge manner. A plurality of rows and columns of springs of the produced mattress are uniformly arranged into a whole, metal frames are arranged on the upper sides and the lower sides of the whole springs, edge supporting hard foam surrounds the peripheries of the springs, gridding cloth sewed with hook-and-loop fasteners tightly wraps the hard foam frames and the springs, and upper filler is fixedly connected with the tops of the springs through the hook-and-loop fasteners. The lower filler is fixedly connected with the bottom of the spring through a sticking buckle; and the upper filler, the lower filler and the peripheral filler are wrapped by the fabric. The mattress is produced in a less-glue or glue-free manner, and the production process is quick and efficient, so that the environmental protection property and comfort of the mattress are improved, and the service life of the mattress can be prolonged.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mattress, in particular to a glue-free mattress and a manufacturing method thereof. BACKGROUND

[0002] Traditional mattress has many deficiencies in structure design and production process. For example, some mattress spring parts lack effective reinforcement and wrapping measures, which leads to spring displacement and deformation during use, affecting the service life and comfort of the mattress; the arrangement of the filler is not reasonable enough to fully meet the needs of different parts of the human body for support and comfort; for mattress made by glue spraying process, the environmental protection and comfort are poor, the waiting time for glue drying is long during the manufacturing process, and the glue is prone to aging and opening; for mattress made by manual point pulling process, the non-integral filler materials such as wool, fur, cotton and fiber in the filling layer are displaced under the action of human body gravity to form pits, and the point pulling buckle on the surface of the mattress brings discomfort to the human body, and the buckle is prone to falling off, and the connection between the parts is not firm enough.

[0003] Therefore, a glue-free mattress and a manufacturing method thereof become a problem to be solved. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a glue-free mattress and a manufacturing method thereof, so that the spring is tightly combined with the filling layer in the mattress, and the problems of fiber material displacement, buckle falling off and discomfort caused by the contact between the buckle and the human body are solved for the traditional manual point pulling process; compared with the glue-sticking mattress, the use of "glue" material in the process of manufacturing the mattress is eliminated or greatly reduced, the environmental protection of the product is improved, the hardening and aging of the filling material caused by glue sticking are overcome, and the comprehensive performance of the mattress is greatly improved.

[0005] To solve the above technical problems, the technical solution provided by the present application is as follows: a mattress production process, comprising the following steps:

[0006] First step: calculate the spring reinforcement frame of the corresponding size, make a metal frame on the upper and lower edges of the spring, and make a triangular reinforcement on the four corners of the metal frame on both sides;

[0007] Second step: increase the hard foam frame with the same height as the spring around the edge of the spring, and connect the hard foam frame with the spring into a whole;

[0008] Third step: calculate the size of the mesh cloth, sew the Velcro at the position of the outer side of the four vertical surfaces of the hard foam frame wrapped by the mesh cloth and the mesh cloth connection; tightly wrap the hard foam frame and the spring with the mesh cloth;

[0009] Or use hot melt glue to connect the spring, the upper and lower mesh cloth and the edge hard foam frame into one body, at this time the mesh cloth is only connected with the hard foam frame in the horizontal plane of the mattress;

[0010] Fourth step: the upper and lower surfaces of the spring are arranged in a regular shape on the mesh cloth with the center line of the top surface evenly to the four sides, and the upper and lower threads are arranged and buckled at the corner points shared by adjacent regular shapes;

[0011] The part made in the first to fourth steps is defined as A part;

[0012] Fifth step: the prepared mattress fabric and filling material are processed by quilting:

[0013] (1) Prepare all materials for quilting according to the specified order of fabric and filling material;

[0014] (2) Arrange each regular shape with a spacing of 8mm to the four sides with double-line quilting, and ensure that the size of the regular shape formed in the fourth step corresponds;

[0015] The part made in the fifth step is defined as B part;

[0016] Sixth step: prepare the fabric and related materials for the four vertical surfaces in front, back, left and right of the mattress;

[0017] Seventh step: process according to the specified material order;

[0018] The part made in the sixth and seventh steps is defined as C part;

[0019] Eighth step: connect A part and C part for processing;

[0020] Ninth step: sew the edges of A part, C part and B part, while ensuring that the buckles on A part are buckled with the corrugated cloth at the adjacent regular shape shared corner points of B part.

[0021] Further, in the fifth step, the specified order of the fabric and filling material is:

[0022] (1) Fabric,

[0023] (2) Super-soft high-density breathable non-woven fabric,

[0024] (3) Silicone mixed fiber / gel cotton / wool / cashmere / camel hair / silk / raw seed cotton,

[0025] (4) Foam / cellular rubber,

[0026] (5) Foam / cellular rubber,

[0027] (6) Super-soft high-density breathable non-woven fabric,

[0028] (7) corrugated cloth.

[0029] Further, the regular shape includes a square, a rectangle, a diamond.

[0030] Further, in the seventh step, the specified material sequence is:

[0031] (1) fabric,

[0032] (2) super-soft high-density breathable non-woven fabric,

[0033] (3) silica gel mixed fiber,

[0034] (4) foam,

[0035] (5) super-soft high-density breathable non-woven fabric,

[0036] (6) corrugated cloth.

[0037] Further, in the eighth step, if the four vertical edges of the mattress are glued to the rigid foam frame with hot melt adhesive, the corrugated cloth is not needed.

[0038] The present application provides a glue-free mattress, comprising springs, edge support rigid foam frames, breathable mesh cloth, Velcro, upper fillers, lower fillers, perimeter fillers, and fabric;

[0039] The springs are arranged in rows and columns and uniformly arranged as a whole, the upper and lower sides of the whole spring are provided with a metal frame reinforced at four corners, the edge support rigid foam frame surrounds the springs, the mesh cloth with Velcro tightly wraps the rigid foam frame and the springs, the upper filler is connected and fixed to the top of the springs through Velcro, the lower filler is connected and fixed to the bottom of the springs through Velcro, the perimeter filler surrounds the edge support rigid foam frame, and its upper edge is connected to the upper filler and its lower edge is connected to the lower filler; the fabric wraps the upper filler, the lower filler, and the perimeter filler.

[0040] Further, the top and bottom of the spring are provided with Velcro, and the two are connected by a drawstring.

[0041] Further, the upper filler is sequentially composed of corrugated cloth, first non-woven fabric, high-hardness super-soft sponge, low-hardness super-soft sponge, silica gel mixed fiber, and second non-woven fabric from the inner layer to the outer layer.

[0042] Further, the upper filler and the lower filler have the same material arrangement from the inner layer to the outer layer, or the silica gel mixed fiber is replaced by / added with other materials.

[0043] Further, the perimeter filler is sequentially composed of corrugated cloth, first non-woven fabric, foam, silica gel mixed fiber, and second non-woven fabric from the inner layer to the outer layer.

[0044] The present application has the advantages compared with the prior art:

[0045] The present application solves the problems of fiber material displacement, easy falling of the pull-off, and uncomfortable feeling caused by the contact between the pull-off and the human body in the traditional manual pull-off process; compared with the adhesive mattress, the use of "glue" material in the process of manufacturing the mattress is eliminated or greatly reduced, the environmental protection of the product is improved, the hardening and easy aging of the filling material caused by the adhesion are overcome, and the comprehensive performance of the mattress is greatly improved. BRIEF DESCRIPTION OF DRAWINGS

[0046] Fig. 1 is a structure diagram of a glue-free mattress based on a spring according to the present application.

[0047] Fig. 2 is a structure diagram of a spring and a breathable mesh cloth connected through a hook-and-loop fastener and a pull rope.

[0048] Fig. 3 is a cross-sectional diagram of a spring and a breathable mesh cloth connected through a hook-and-loop fastener and a pull rope.

[0049] As shown in the figure: 1, spring, 2, edge support hard foam frame, 3, fabric, 4, breathable mesh cloth, 5, corrugated cloth, 6, first non-woven fabric, 7, high-hardness super-soft sponge, 8, low-hardness super-soft sponge, 9, silica gel mixed fiber, 10, second non-woven fabric, 11, foam, 12, hook-and-loop fastener, 13, pull rope. DETAILED DESCRIPTION

[0050] In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "inner", "outer", "vertical", "circumferential" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements indicated must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0051] In the description of the present application, "first feature" and "second feature" can include one or more of the features. In addition, the terms "first" and "second" are only for the purpose of description, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined with "first" and "second" can explicitly or implicitly include one or more of the features.

[0052] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting", "fixing" and the like should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be connected inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0053] The present application is further described in detail below in combination with the drawings.

[0054] In combination with the drawings Figs. 1-3 The specific implementation process of the present application, a glue-free mattress and its manufacturing method, is as follows:

[0055] Example 1

[0056] A spring-based glue-free mattress production process, comprising the following steps:

[0057] Step 1: Spring reinforced frame manufacturing

[0058] Calculate the spring reinforced frame of the corresponding size, make a metal frame for the spring upper and lower edge. Through the metal frame, the spring edge is reinforced to enhance the stability of the spring and prevent the spring from deforming and shifting during the mattress handling and use.

[0059] Step 2: Hard foam frame installation

[0060] Add a hard foam frame around the edge of the spring and connect it to the spring as a whole. The hard foam frame can play the role of connecting the spring and the bed edge softly and supporting the bed edge, improving the comfort of the mattress, and further fixing the position of the spring.

[0061] Step 3: Spring part wrapping

[0062] There are two wrapping methods to choose from:

[0063] (1) Calculate the size of the mesh cloth according to the corresponding size, sew the Velcro at the position of the mesh cloth wrapping the four vertical sides of the hard foam frame and the mesh cloth connection; use the mesh cloth to tightly wrap the hard foam frame and the spring; this way can be easily installed through Velcro, avoiding the use of glue and overcoming the disadvantages caused by glue aging.

[0064] (2) Use hot melt glue to connect the spring, the upper and lower mesh cloth and the edge hard foam frame into one body, at this time the mesh cloth is only connected with the hard foam frame in the horizontal plane of the mattress. The hot melt glue connection method can make the parts tightly combined, improving the overall structural stability of the mattress.

[0065] Fourth step: Velcro arrangement

[0066] The spring upper and lower surfaces are arranged in a regular shape with the top surface centerline evenly distributed to the four sides on the mesh cloth. The velcro is arranged by threading and arranging the velcro at the top points of the regular shape connected to each other (this process is completed by using a "mattress special pull point machine"). The regular shape can be a square 264*264mm (size can be adjusted), rectangle, diamond, etc.

[0067] The part made in the first to fourth steps is defined as part A.

[0068] Fifth step: Mattress surface quilting process

[0069] Prepare all materials for quilting according to the specified order of the fabric and filler materials.

[0070] (1) Fabric,

[0071] (2) Super soft high-density breathable non-woven fabric,

[0072] (3) Silicone mixed fiber / glue-free cotton / wool / cashmere / camel hair / silk / raw seed cotton, among which high-quality products generally use silicone mixed fiber, ordinary products use glue-free cotton, and high-end products can choose to use cashmere / camel hair in winter and silk / raw seed cotton in summer;

[0073] (4) Foam / natural latex, etc.,

[0074] (5) Foam / natural latex, etc.,

[0075] (6) Super soft high-density breathable non-woven fabric,

[0076] (7) Corrugated cloth.

[0077] Arrange 260*260mm (size can be adjusted) evenly to the four sides with the centerline of the mattress surface, quilt with double threads every regular shape with a distance of 8mm, and ensure that the size corresponds to the regular shape formed in the fourth step. This quilting method can make the filler evenly distributed and locked inside the regular shape area, improving the flatness of the mattress surface and maintaining its comfort.

[0078] The part made in the fifth step is defined as part B.

[0079] Sixth step: Mattress vertical surface material preparation

[0080] Prepare the fabric and related materials for the four vertical surfaces of the mattress.

[0081] Seventh step: Vertical surface quilting process

[0082] Quilting process according to the specified material order, the specific order is:

[0083] (1) fabric,

[0084] (2) super-soft high-density breathable non-woven fabric,

[0085] (3) silicone mixed fiber or others,

[0086] (4) foam or others,

[0087] (5) super-soft high-density breathable non-woven fabric,

[0088] (6) corrugated fabric.

[0089] If the four vertical edges of the mattress are glued to the rigid foam frame with hot melt adhesive, there is no need to use corrugated fabric.

[0090] The part made in the sixth step and the seventh step is defined as C part.

[0091] Step 8: A part and C part processing connection

[0092] The A part and C part are processed and connected to complete the core and side of the mattress to form a whole structure.

[0093] Step 9: whole edge sewing

[0094] The A part and C part are sewn with the B part, completing the overall assembly of the mattress, while ensuring that the Velcro on the A part is glued to the corrugated fabric at the adjacent regular shape sharing corner point of the B part.

[0095] Example 2

[0096] A glue-free mattress based on springs, comprising springs 1, edge support rigid foam frame 2, breathable mesh fabric 4, upper filler, lower filler, four around filler and fabric 3.

[0097] The springs 1 are arranged in rows and columns and uniformly arranged as a whole, and the upper and lower sides of the whole spring 1 are provided with a metal frame with triangular reinforcement at the corners, which can provide stable support for the springs 1 and prevent the springs 1 from deforming during transportation and use.

[0098] The edge support rigid foam frame 2 surrounds the springs 1, which plays a role in connecting and smoothly transitioning between the springs and the soft support of the mattress edge, improving the overall comfort of the mattress and enhancing the support of the mattress edge, preventing the edge from collapsing.

[0099] The material of the upper filler and the lower filler is arranged in the same way from the inner layer to the outer layer, specifically in turn, the corrugated cloth 5, the first non-woven fabric 6, the high-hardness super-soft sponge 7, the low-hardness super-soft sponge 8, the silica gel mixed fiber 9, and the second non-woven fabric 10. The multi-layer structure of the filler can provide different support and comfort according to the needs of different parts of the human body. The air-permeable mesh cloth 4 plays a coupling role between the spring and the filling material, while ensuring the air permeability of the mattress; the corrugated cloth 5 can ensure the close connection with the hook and loop 12 above the air-permeable mesh cloth 4, so that the upper and lower layers of the mattress form a firm whole; the first non-woven fabric 6 plays a role in wrapping the middle filler material into a whole with the fabric 3; the high-hardness super-soft sponge 7 can provide support; the low-hardness super-soft sponge 8 provides soft comfort; the silica gel mixed fiber 9 provides moisture absorption, air permeability, support and comfort to the mattress; the second non-woven fabric 10 plays a role in closing the silica gel mixed fiber 9 to prevent the fiber material from escaping; the first non-woven fabric 6 and the second non-woven fabric 10 both use super-soft high-density air-permeable non-woven fabric to increase the air permeability of the product, while different gram weights are generally selected according to their different roles. According to actual needs, the upper filler and the lower filler can also partially use different materials, for example, to adapt to the switching between winter and summer, the upper filler uses silk or raw seed cotton instead of silica gel mixed fiber 9 or is used in combination, the lower filler uses wool, cashmere or camel hair instead of silica gel mixed fiber 9 or is used in combination, and the high-hardness super-soft sponge 7 and the low-hardness super-soft sponge 8 can be replaced by one kind of material, such as latex.

[0100] The upper filler is connected and fixed with the top of the spring 1 through the hook and loop 12, the lower filler is connected and fixed with the bottom of the spring 1 through the hook and loop 12, and the hook and loop 12 at the top of the spring 1 and the hook and loop 12 at the bottom of the spring 1 are connected through the drawstring 13 to pull the air-permeable mesh cloth 4 tightly around the spring 1, while the hook and loop 12 uses the hook surface of the Velcro, which can effectively and tightly adhere and fix the corrugated cloth 5.

[0101] The four-around filler is in turn the first non-woven fabric 6, the foam 11, the silica gel mixed fiber 9, and the second non-woven fabric 10 from the inner layer to the outer layer, surrounds the four-around hard foam 2, and its upper edge is connected with the upper filler and its lower edge is connected with the lower filler, which can further enhance the overall structural stability of the mattress.

[0102] The fabric 3 wraps the upper filler, the lower filler, and the four-around filler, playing a protective and decorative role.

[0103] The above describes the present application and its embodiments, which are not limited, and the drawings only show one of the embodiments of the present application, and the actual structure is not limited thereto. For example, the hard foam frame around the spring can not be used, and the spring can be directly extended to the edge of the mattress. In actual application, the comfort of the edge of the mattress will be poor, and the same can be used. The filling layer is appropriately increased in material or changed in material, etc. In summary, if a person skilled in the art is inspired thereby, without departing from the purpose of the present application, without creative design, similar structure and embodiments of the technical solution are not creative design, and should belong to the protection scope of the present application.

Claims

1. A glue-free mattress and its manufacturing method, characterized in that: Includes the following steps: Step 1: Calculate the spring reinforcement frame of the corresponding specifications and size, make metal frames for the top and bottom edges of the spring, and make triangular reinforcements at the four corners of the metal frames on both sides. Step 2: Add a rigid foam frame of the same height as the spring around the four edges of the spring and connect it to the spring to form a whole; Step 3: Calculate the appropriate size of mesh fabric, and sew Velcro fasteners on the outer sides of the four vertical surfaces of the rigid foam frame and at the joints of the mesh fabric; use the mesh fabric to tightly wrap the rigid foam frame and springs. Alternatively, hot melt adhesive can be used to connect the springs, upper and lower mesh fabrics, and edge rigid foam frame into one piece. In this case, the mesh fabric is only bonded to the rigid foam frame on the horizontal surface of the mattress. Step 4: Arrange the springs on the mesh fabric in a regular shape with the center line of the top surface outwards. Thread the springs through the mesh fabric at the corners shared by adjacent regular shapes and arrange the hook and loop fasteners. The parts created in steps one through four are defined as part A. Step 5: Quilt the prepared mattress fabric and filling materials: (1) Prepare all quilting materials in the specified order of fabric and filling materials; (2) Arrange the regular shapes outwards from the center line of the mattress surface, with each regular shape spaced 8mm apart and double-stitched, ensuring that the dimensions correspond to the regular shapes formed in step four; Define the part created in step five as part B; Step 6: Prepare the fabric and related materials for the four vertical surfaces of the mattress (front, back, left, and right); Step 7: Perform quilting according to the prescribed material sequence; Define the parts created in steps six and seven as part C; Step 8: Complete the machining and connection of part A and part C; Step 9: Sew the edges of parts A, C, and B together, while ensuring that the hook and loop fasteners on part A are attached to the corrugated fabric of part B at the corners where they share a common shape.

2. The mattress manufacturing process according to claim 1, characterized in that: In step five, the prescribed order of the fabric and filling materials is as follows: (1) Fabric, (2) Ultra-soft, high-density, breathable non-woven fabric (3) Silicone-blended fiber / non-adhesive cotton / wool / cashmere / camel hair / silk / raw cotton, (4) Foam / natural latex, (5) Foam / natural latex, (6) Ultra-soft, high-density, breathable non-woven fabric (7) Corrugated fabric.

3. The mattress manufacturing process according to claim 2, characterized in that: The regular shapes include squares, rectangles, and rhombuses.

4. A mattress manufacturing process according to claim 3, characterized in that: In step seven, the specified material order is as follows: (1) Fabric, (2) Ultra-soft, high-density, breathable non-woven fabric (3) Silicone-blended fibers, (4) Foam, (5) Ultra-soft, high-density, breathable non-woven fabric (6) Corrugated fabric.

5. A mattress manufacturing process according to claim 4, characterized in that: In step eight, if the four vertical edges of the mattress are bonded to the rigid foam frame with hot melt adhesive, then corrugated fabric is not required.

6. A glue-free mattress, characterized in that: Includes springs, edge-supporting rigid foam, mesh fabric, hook and loop fasteners, top filling, bottom filling, perimeter filling, and fabric; The spring has several rows and columns arranged evenly as a whole. The upper and lower sides of the whole spring are provided with metal frames reinforced at the four corners. The edge support rigid foam surrounds the spring. The mesh fabric with hook and loop fasteners tightly wraps the rigid foam frame and the spring. The upper filling is fixed to the top of the spring with hook and loop fasteners. The lower filling is fixed to the bottom of the spring with hook and loop fasteners. The surrounding filling surrounds the edge support rigid foam, and its upper edge is connected to the upper filling and its lower edge is connected to the lower filling. The fabric wraps the upper filling, the lower filling and the surrounding filling inside.

7. A glue-free mattress according to claim 6, characterized in that: The spring has hook-and-loop fasteners at both the top and bottom, and the two are connected by a pull cord.

8. A glue-free mattress according to claim 7, characterized in that: The upper filling material consists of, from the inner layer to the outer layer, corrugated fabric, first nonwoven fabric, high-hardness ultra-soft sponge, low-hardness ultra-soft sponge, silicone mixed fiber, and second nonwoven fabric.

9. A glue-free mattress according to claim 8, characterized in that: The upper and lower fillers are made of the same material from the inner to the outer layer, or the silicone-mixed fibers can be replaced with / added to other materials.

10. A glue-free mattress according to claim 9, characterized in that: The surrounding filling material, from the inner layer to the outer layer, consists of corrugated fabric, first non-woven fabric, foam, silicone mixed fiber, and second non-woven fabric.

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