Cover body of bed mattress and sewing method for the same

Abstract

To solve the problems that a soft inner material of a bed mattress inhibits the flatness due to being compressed by a cover body, and as a result, linearity of an edge part of a border line between flat surfaces in a corner part is damaged, and there is a possibility that the aesthetic quality as designed is not expressed.SOLUTION: A cover body for covering an inner material of a bed mattress is such that: a corner part of the inner material includes a pair of perpendicularly arranged flat parts, and an edge part between the pair of flat parts; the cover body includes a corner covering part for covering the corner part of the inner material; the corner covering part is formed of a continuous cloth; the corner covering part has a variable part facing the edge part of the inner material, and a sheet part facing the flat part; and the variable part has lower shape retention than the sheet part.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an improvement in a cover body for a bed mattress and a sewing method thereof. [Background technology]

[0002] The bed mattress comprises a cushioning material and a cover body that covers the cushioning material. In order to facilitate washing and to easily change the design, it is preferable that the cover be detachable from the inner material. Please refer to Patent Document 1 as a document disclosing a technique related to the present invention. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-81382 A Summary of the Invention [Problem to be solved by the invention]

[0004] The cushioning properties of the inner material of a bed mattress are adjusted in various ways depending on the manner in which the bed mattress is required to be used. When softness was required for the filling of a bed mattress, the following problems arose: In order to prevent wrinkles from forming on the surface of the cover body, it is common for the cover body to be tightly covered by the inner material. In this case, if the inner material of the bed mattress is soft, the inner material is compressed in the thickness direction by the cover body, and the side of the bed mattress is deformed. In a bed mattress with a plate-shaped inner material, the upper surface and side surfaces should be flat. However, if the inner material is soft, it is compressed by the cover body, and the side of the inner material bulges outward or wrinkles, hindering its flatness. As a result, the straightness of the boundary line between the upper surface (or lower surface) and the side surface, or the edge of the boundary line between the side surfaces, is impaired at the corners of the bed mattress, and there is a risk that the design as designed will not be expressed.

[0005] By preparing multiple pieces of fabric, sewing their edges together to form a cover body, and then facing the sewn edges to the edges of the inner material, it is possible to ensure the linearity of the part of the cover body facing the edges. However, sewing multiple pieces of fabric together is time-consuming, and if there is a sewn part in the corner covering part of the cover body, when it is faced to the corner part of the inner material, the corner covering part cannot completely follow the corner part of the inner material, and a small space is created between the two. This space may impair the design of the corner part of the bed mattress. [Means for solving the problem]

[0006] The present invention has been made to solve the above problems, and a first aspect of the present invention is defined as follows. A cover body for covering the inner material of a bed mattress, The corner portion of the inner material has a pair of flat portions vertically arranged and an edge portion between the pair of flat portions, The cover body includes a corner covering portion that covers a corner portion of the inner material, the corner covering comprises a continuous piece of fabric; The corner covering portion has a variable portion facing the edge portion of the inner material and a sheet portion facing the flat portion, and the variable portion has a smaller shape retention than the sheet portion. Cover body.

[0007] According to the cover body defined in this way, the variable part of the corner covering part faces the edge of the corner part of the inner material, and the sheet part of the corner covering part faces the flat part of the inner material, so that the corner covering part faces the corner part of the inner material without any gaps. This is because the corner covering part is made of a continuous fabric, so that it is difficult for a space to be formed between the cover body and the inner material, and because the variable part facing the edge of the inner material has low shape retention, it deforms preferentially. In other words, the stress of the cover body is concentrated on the variable part, so the deformation of the sheet part is suppressed.

[0008] The corner covering portion of the cover body suppresses deformation of the sheet portion, thereby suppressing deformation of the side, upper and lower surfaces of the bed mattress and maintaining its flatness. The suppression of deformation of the side, upper and lower surfaces of the mattress also maintains the straightness of the edges connecting these flat surfaces. The deformation of the corner covering part is concentrated on the variable part with low shape retention. In other words, even if the variable part with low shape retention is deformed, it does not deform the edge of the core material, but only follows and deforms along the edge. Therefore, the straightness of the edge of the core material is maintained.

[0009] The cover body defined in the second aspect of the present invention is defined as follows. In the cover body defined in the first aspect, the sheet portion of the corner covering portion is formed by folding a part of the continuous fabric and sewing it. According to the cover body of the second aspect thus defined, the shape retention of the seat portion is increased by folding and sewing the fabric. Since the fabric constitutes the corner covering portion including the deformation portion, the number of components of the cover body can be reduced as much as possible. Therefore, the manufacturing cost of the cover body can be reduced.

[0010] The cover body defined in the third aspect of the present invention is defined as follows. In the cover body defined in the first aspect, the sheet portion at the corner portion is reinforced with another member. According to the cover body of the third aspect thus defined, the shape retention of the sheet portion can be increased by reinforcing the sheet portion with other members. By selecting the material of the other members, the degree of reinforcement of the sheet portion can be adjusted as desired. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic diagram showing the relationship between the inner material and the cover body. [Diagram 2] FIG. 2 is a schematic diagram showing a state in which the inner material is covered with the cover body according to the embodiment of the present invention. [Diagram 3] FIG. 3 is a schematic diagram showing a state in which a middle material is covered with a cover body according to another embodiment of the present invention. [Figure 4] FIG. 4 is a schematic diagram showing a cover body according to another embodiment of the present invention and the state in which the cover body covers a middle material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, an embodiment of the present invention will be described. FIG. 1 shows a core material 10 and a cover body 20, FIG. 1A shows the core material 10, FIG. 1B shows the cover body 20, and FIG. 1C shows a bed mattress 1 in which the core material 10 is covered with the cover body 20.

[0013] The inner material 10 is a plate-shaped cushion member. The cushion member can be selected arbitrarily depending on the purpose and usage of the bed mattress. For example, a filament three-dimensional bond (product name: Air Fiber manufactured by Airweave Co., Ltd.), polyurethane foam, etc. can be selected. The inner material 10 may be made of the same material throughout, or may be made of different materials (materials, degree of foaming) in the thickness direction and / or width direction in order to adjust the hardness and resilience. The shape of the core material 10 can be designed arbitrarily depending on the bed that will be the base, but it is generally made in the form of a thin rectangular plate.

[0014] Therefore, the core 10 has a top surface 11 and side surfaces 12, 13 which are orthogonal flat portions, and each flat portion has linear edges 15, 16 and 17. At least one pair of flat portions and edges forms a corner portion. For example, the side surfaces 12, 13 and edge 15 form a corner portion 19. In this example, the core material 10 is a three-dimensional filament bond having a height of 10 to 600 mm, a width of 300 to 2500 mm, and a length of 1000 to 2500 mm.

[0015] The cover body 20 is made of cloth and is a bag body having the same outer diameter as the outer dimensions of the inner material 10. To store the inner material 10, one side can be opened and closed by a linear fastener. The reference numeral 21 in the figure denotes a corner covering portion, which faces the corner portion of the core material 10. In the following explanation, attention will be focused on the corner portion 19 where the side surface 12 and the side surface 13 of the core material 10 are connected by the edge 15, and the corner covering portion 21.

[0016] A detailed configuration of the corner covering portion 21 of the cover body 20 is shown in FIG. 2A. The corner covering portion 21 is made of a single piece of fabric 25 and includes a variable portion 22 and a sheet portion 23. The variable portion 22 is sandwiched between the sheet portions 23, and the fabric 25 is not folded at all in the variable portion 22 and is a single piece. In the sheet portion 23, the fabric 25 is folded downward from the variable portion 22, and is folded three times and sewn with reinforcing thread 27. According to the corner covering part 21 configured in this manner, the fabric 25 is continuous on the design surface (uppermost surface). This allows a unique design to be imparted to the corner covering part 21. For example, it becomes easy to form a pattern on the corner covering part 21.

[0017] In the example of Fig. 2(B), the edge of the sheet portion 23 (the edge opposite the variable portion 22) is set to the middle of the flat portion 12 or the flat portion 13. If the corner covering portion 21 of the cover body 20 performs its function to not deform the corner portion 19 of the inner material 10 in any way and is made to follow its original shape, the design of the bed mattress is not impaired. Of course, the sheet portion of the cover body 20 may be provided so as to face the entire surface of the flat portion 12 and the flat portion 13 of the inner material 10, or the relatively short sheet portion 23 shown in FIG. 2(A) may be repeatedly arranged.

[0018] The degree of folding (overlapping) of fabric 25 in sheet portion 23 is selected as desired in consideration of the bendability of fabric 25 itself, the density of stitching, etc., and in accordance with the shape retention required of sheet portion 23. In order to pull out the edge of fabric 25 from sheet portion 23, the number of folds is an odd number of 3 or more. As long as sufficient shape retention can be ensured for the sheet portion 23, the stitching density can be selected as desired.

[0019] The stitching pattern is arbitrary, and by adopting a general-purpose sashiko pattern, the sheet portion 23 can be given any design. The color and thickness of the reinforcing thread 27 can be freely selected. For ease of sewing, it is preferable to sew the sheet portion 23 with one reinforcing thread 27, but it is also possible to sew the fabric of one sheet portion 23 using multiple reinforcing threads 27, each of which may be of a different color or may be formed into a sashiko pattern.

[0020] The cover body 20 shown in FIG. 2 can be formed as follows. A continuous piece of fabric 25 is prepared. The width of the piece of fabric 25 is at least three times the combined width of the flat portions 12 and 13 of the inner material 10. Next, the portion facing the edge of the inner material 10, i.e., the variable portion 22, is defined. At this time, fabric having a width three times or more the width of the flat portion 12 and the flat portion 13 is provided on both sides of the variable portion 22. Next, the fabric 25 on both sides of the variable portion 22 is folded in three and temporarily secured with a needle, tape or the like. The folded part is sewn together with a stab stitch.

[0021] In the cover body 20 thus formed, the shape retention of the variable portion 22 having one layer of fabric 25 is smaller than the shape retention of the sheet portion 23 having three layers of fabric 25 reinforced by sewn seams. As a result, when the cover body 20 tightly covers the inner material 10, the variable portion of the corner covering portion of the cover body deforms to fit the edge of the inner material 10, maintaining its linearity, while the highly shape-retaining sheet portion faces the flat portion of the inner material and maintains its flatness.

[0022] Fig. 3 shows a corner covering portion 121 of a cover body according to another embodiment. Note that the same elements as those in Fig. 2 are given the same reference numerals and their explanation will be omitted. This corner covering part 121 has a structure in which a variable part 122 is sandwiched between sheet parts 123, 123, and the sheet parts 123, 123 and the variable part 122 are connected by a continuous fabric 25. A reinforcing sheet 130 is attached to the back surface of the sheet part 123 (the surface facing the inner material 10), making the shape retention of the sheet part 123 greater than that of the variable part 122.

[0023] By attaching the reinforcing sheet 130 to the back surface of the sheet portion 123, the continuous fabric 25 appears in a plain state on the front surface of the corner covering portion 121. This gives the corner covering portion 121 a simple design. In the above example, the reinforcing sheet 130 is attached to the back surface of the sheet portion 123, but it is also possible to provide a bag in the sheet portion 123 and insert the reinforcing sheet therein. This does not avoid sewing the reinforcing sheet 130 to the fabric of the sheet portion 123. There are no particular limitations on the material of the reinforcing sheet 130, so long as it is a material with higher rigidity than the fabric 25. A thin plate of a flexible polymer material such as a foam material can be used.

[0024] Fig. 4 shows a corner covering portion 221 of a cover body according to another embodiment. Note that the same elements as those in Fig. 2 are given the same reference numerals and their explanation will be omitted. This corner covering portion 221 has a structure in which a variable portion 222 is sandwiched between sheet portions 223, 223, and the sheet portions 223, 223 and the variable portion 222 are connected by a continuous piece of fabric 25.

[0025] In this example, a short second folded portion 2231 is provided at a portion of the sheet portion 223 that connects to the variable portion 222. The fabric 25 is also folded at this second folded portion 2231, but the stitching density of the reinforcing thread 27 is smaller than that of the main body portion 2233 of the variable portion 222, and the shape retention is set to the size between the main body portion 2233 and the variable portion 222. This allows smooth deformation between the variable portion 222 and the seat portion 223.

[0026] By providing the second folded portion 2231, the width of the variable portion 222 can be made narrower. The width of the second folded portion 2231 is not particularly limited, but may be the same as the width of the variable portion 222 or twice as wide.

[0027] The present invention is not limited to the above-mentioned embodiment and examples. Various modifications within the scope of the claims and within the scope that can be easily conceived by a person skilled in the art are also included in the present invention. [Explanation of symbols]

[0028] 1 Bed Mattress 10 Filling material 11, 12, 13 flat surface 15, 16, 17 Edge 19 Corner section 20 Cover body 21, 121, 221 Corner covering section 22, 122, 222 Variable part 23, 123, 223 Seat section 27 Reinforcing thread 130 Reinforcement sheet

Claims

1. A cover body for covering the inner material of a bed mattress, The corner portion of the inner material has a pair of flat portions vertically arranged and an edge portion between the pair of flat portions, The cover body includes a corner covering portion that covers a corner portion of the inner material, the corner covering comprises a continuous piece of fabric; The corner covering portion has a variable portion facing the edge portion of the inner material and a sheet portion facing the flat portion, and the variable portion has a smaller shape retention than the sheet portion. Cover body.

2. The cover body according to claim 1 , wherein the sheet portion of the corner covering portion is formed by folding a portion of the continuous fabric and sewing it.

3. The cover body according to claim 1 , wherein the sheet portion at the corner portion is reinforced with another member.

4. A bed mattress comprising the inner material covered with the cover body according to claim 1.

5. A method for manufacturing the cover body according to claim 2, comprising the steps of: providing the continuous fabric; defining a variable portion of the continuous fabric opposite an edge of the filler; folding both ends of the variable portion over the continuous fabric; stitching the folded portion; A method for manufacturing a cover body comprising the steps of:

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