Cushioning material and cushioning material assembling method

Abstract

To provide a cushioning material capable of reducing a manufacturing cost while maintaining air permeability and comfort.SOLUTION: A cushioning material comprises: a three-dimensional structure which is formed in a mesh shape from a polyester fiber 30, the outer peripheral part of which is formed in such a manner that a rectangular fiber layer body 20 melted by heat treatment using a hot air gun for emitting hot air at 400°C is sewn while a part of the outer peripheral part is left as an opening F, and which is formed like a bag by being turned inside out; and a finally-sewn part 15 which is positioned in the opening F and formed by being sewn.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a cushioning material formed into a high-rebound three-dimensional structure by being knitted in a mesh shape with resin fibers, and a method for assembling the cushioning material.

Background Art

[0002] Foamed polyurethane and air cushioning materials are known as cushioning materials for futons, bedding, various sheets, etc. Since these cushioning materials are inferior in air permeability, fibers may be formed into a mesh shape to form a fiber layer, and the ends thereof may be sewn together to form a three-dimensional structure as a whole to obtain a cushioning material having high air permeability (see, for example, Patent Document 1). As the fibers used for such cushioning materials, resin fibers such as polyester fibers are used because they have high resilience and are also excellent in durability, cost, ease of manufacture, etc. Such a cushioning material is stored in a bag-shaped cover material with a good texture so that the cushioning material itself does not touch the user.

[0003] In a cushioning material formed by forming resin fibers into a mesh shape to form a three-dimensional structure, since the resin fibers are very rigid, even when sewn, there is a risk of piercing through the cover material and irritating the user's skin, giving the user discomfort. For this reason, it is known to sew the outer periphery of the cushioning material with an edge cover material (see Patent Document 2).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the cushioning material in which resin fibers are formed into a mesh shape to form a three-dimensional structure as described above, there were the following problems. That is, when the outer peripheral portion of the fiber layer is sewn to form a three-dimensional structure, it is necessary to sew the outer periphery of the cushioning material with an edge covering material in order to prevent the resin fibers from piercing through the covering material. This requires an extra member for the edge covering material, and the increase in work increases the manufacturing cost. In addition, the edge covering material has high airtightness to prevent the resin fibers from piercing through, and there is also a problem that the air permeability is poor on the outer peripheral side.

[0006] Therefore, an object of the present invention is to provide a cushioning material and a method for assembling a cushioning material that can reduce the manufacturing cost while maintaining air permeability and comfort.

Means for Solving the Problems

[0007] The present invention is formed into a mesh shape by resin fibers, and two rectangular fiber layer bodies whose outer peripheral portions are melted by heat treatment are sewn with a part of their outer peripheral portions left as an opening, and are formed into a bag shape by turning inside out, and a three-dimensional structure, and a final sewing portion formed by sewing and located at the opening.

[0008] The present invention melts the outer peripheral portion of a single rectangular fiber layer body formed into a mesh shape by resin fibers, bends the fiber layer body at the center, sews with a part of its outer peripheral portion left as an opening, pulls out the inside of the fiber layer body from the opening, turns it inside out, and sews the opening.

[0009] Melt the outer peripheral portions of two rectangular fiber layer bodies formed into a mesh shape by resin fibers, stack the fiber layer bodies, sew with a part of their outer peripheral portions left as an opening, pull out the inside of the fiber layer bodies from the opening, turn them inside out, and sew the opening.

Effects of the Invention

[0010] According to the cushioning material of the present invention, it is possible to reduce the manufacturing cost while maintaining air permeability and comfort.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0013] FIG. 1 is a perspective view showing the cushioning material 10 which is an embodiment of the present invention, FIG. 2 is a plan view showing the fiber laminate 20 before assembly of the cushioning material 10, FIG. 3 is an explanatory view showing the assembly process of the cushioning material 10, FIG. 4 is an explanatory view showing the final stitching part in the cushioning material 10, FIG. 5 is an explanatory view showing the assembly process of the cushioning material 10, and FIG. 6 is an explanatory view showing the assembly process of the cushioning material 10 of the present embodiment.

[0014] As shown in Fig. 1, the cushioning material 10 as a highly resilient three-dimensional structure has a fiber laminate 20 in a folded state, with a long side of approximately 2 m and a short side of approximately 1 m. Note that the dimensions of the cushioning material 10 can be changed as required. The cushioning material 10 includes a bent portion 11, side end portions 12 located on the opposite side of the bent portion 11, an upper end portion 13, and a lower end portion 14. A final stitching portion 15 is formed at the lower end portion 14. The fiber laminate 20 is formed in a mesh shape by knitting polyester fibers 30 such as raschel knitting.

[0015] The cushioning material 10 configured as described above is assembled as follows. As shown in Fig. 2, the fiber laminate 20 before assembly is formed into a square with a long side and a short side of approximately 2 m each. The fiber laminate 20 has portions 21 to 27. That is, portion 21 is the left end portion, portion 22 is the central portion, portion 23 is the right end portion, portion 24 is the upper left portion, portion 25 is the upper right portion, portion 26 is the lower left portion, and portion 27 is the lower right portion.

[0016] For portions 21 to 27, heat treatment is performed using a hot air gun (heat gun) that ejects hot air at approximately 400°C. As a result, the tips 31 of the polyester fibers 30 are melted. Thereby, the tips 31 of the polyester fibers 30 disappear.

[0017] Next, as shown in Fig. 3, it is bent at portion 22 so that portion 21 and portion 23 overlap. As a result, portion 24 and portion 25, and portion 26 and portion 27 overlap. Next, portion 21 and portion 23, portion 24 and portion 25, and portion 26 and portion 27 are sewn together to form a three-dimensional structure. Note that when sewing portion 26 and portion 27, the portion corresponding to the aforementioned final stitching portion 15 is not sewn, and an opening F with a length of approximately 30 cm is formed. Note that the broken line S in the figure indicates the stitching portion. Thereby, the fiber laminate 20 becomes a bag shape having an opening F.

[0018] Next, insert a hand through the opening F of the fiber laminate 20, pull out the portions 24 and 25 from the opening F, and turn the entire fiber laminate 20 inside out to form a bag shape. As a result, as shown in FIG. 4, the stitching portion S will be located inside the fiber laminate 20. Note that by turning it inside out, the three-dimensional structure starting from the stitching portion S becomes more prominent.

[0019] Finally, as shown in FIG. 5, close the opening F by hand sewing to form the final stitching portion 15.

[0020] The cushioning material 10 as the highly resilient three-dimensional structure configured in this way can be structured such that the tips 31 of the polyester fibers 30 do not protrude outward by heat-treating the periphery of the fiber laminate 20 in advance. Therefore, it is possible to prevent the polyester fibers 30 from protruding during use and disturbing the comfort of the user. Also, there is no need to sew the outer peripheral portion with an edge covering material during assembly, eliminating the need for an extra member for the edge covering material and reducing unnecessary work. Therefore, the manufacturing cost can be suppressed. In addition, since there is no need to use an edge covering material with high airtightness, high breathability can be maintained on the outer peripheral side as well. Additionally, since the stitching portion S is on the inside, the stitching portion S is less likely to come loose during washing of the cushioning material 10, increasing the durability.

[0021] Since the cushioning material 10 is in a bag shape, additional cushioning materials, deodorants, fragrances, temperature and humidity regulating materials, etc. may be accommodated inside before sewing the opening F.

[0022] FIG. 7 is a plan view showing the fiber laminates 20A and 20B used for the cushioning material 10 of the present embodiment. In FIG. 7, the same reference numerals are given to the same functional portions as in FIG. 2, and detailed descriptions are omitted.

[0023] The difference between the fiber laminate 20 and the fiber laminates 20A and 20B is whether one sheet is bent to form a three-dimensional structure or two sheets are overlapped to form a three-dimensional structure.

[0024] As shown in FIG. 7, the cushioning material 10 as a highly resilient three-dimensional structure has a pair of fiber laminates 20A and 20B. Both of the fiber laminates 20A and 20B are rectangles with a length of approximately 2 m on the long side and a length of approximately 1 m on the short side. The fiber laminates 20A and 20B are formed in a mesh shape by using polyester fibers 30 and knitting them by raschel knitting or the like.

[0025] Therefore, the fiber laminate 20A is provided with portions 21, 22a, 24, and 26. The portion 22a corresponds to the portion 22 in FIG. 2. Similarly, the fiber laminate 20B is provided with portions 22b, 23, 25, and 27. The portion 22b corresponds to the portion 22 in FIG. 2.

[0026] When using the fiber laminates 20A and 20B, the cushioning material 10 is assembled as follows. That is, the portions 21, 22a, 24, and 26 of the fiber laminate 20A and the portions 22b, 23, 25, and 27 of the fiber laminate 20B are heat-treated with a hot air gun that ejects hot air at about 400°C. As a result, the tips 31 of the polyester fibers 30 are melted. As a result, the tips 31 of the polyester fibers 30 disappear.

[0027] Next, the portions 21 and 23, the portions 22a and 22b, the portions 24 and 25, and the portions 26 and 27 are arranged so as to overlap. Next, the portions 21 and 23, the portions 22a and 22b, the portions 24 and 25, and the portions 26 and 27 are sewn together with a sewing machine to form a three-dimensional structure. When sewing the portions 26 and 27, the portion corresponding to the final sewing portion 15 described above is not sewn, and an opening F with a length of about 30 cm is formed.

[0028] Next, insert a hand through the opening F of the fiber laminates 20A and 20B, pull out the portions 24 and 25 from the opening F, and turn the entire fiber laminates 20A and 20B inside out to form a bag shape. As a result, the sewing portion S will be located inside the fiber laminates 20A and 20B.

[0029] Finally, the opening F is sewn by hand to form the final sewing portion 15.

[0030] The cushioning material 10 as a highly resilient three-dimensional structure configured as described above can be structured such that the tips 31 of the polyester fibers 30 do not protrude outward by heat-treating the periphery of the fiber layers 20A and 20B in advance. Therefore, it is possible to prevent the comfort of the user from being impaired by the protrusion of the polyester fibers 30 during use. In addition, there is no need to sew the outer peripheral portion with an edge cover material during assembly, eliminating the need for an extra member for the edge cover material and reducing unnecessary work. Therefore, the manufacturing cost can be suppressed. In addition, since the stitching portion S is on the inner side, the stitching portion S is less likely to come loose during washing of the cushioning material 10, increasing the durability.

[0031] Since the cushioning material 10 is in a bag shape, additional cushioning materials, deodorants, fragrances, temperature and humidity control materials, etc. may be housed inside before sewing the opening F.

[0032] As described above, the embodiments of the present invention have been described, but it goes without saying that the present invention is not limited to this and various improvements and modifications can be made without departing from the spirit thereof.

[0033] For example, in the above-described example, polyester fibers are exemplified as the resin fibers, but other resin fibers may be used. Also, although sewing machine sewing and hand sewing are exemplified as the sewing means, it is not limited thereto. Furthermore, in addition to a hot air gun, steam treatment or the like can also be applied to the heat treatment of the tips of the polyester fibers. In addition, the knitting method, the number and shape of the fiber layers, dimensions, etc. can be deformed as needed.

Industrial Applicability

[0034] The present invention is effective as a cushioning material formed in a mesh shape by resin fibers and formed as a highly resilient three-dimensional structure.

Explanation of Signs

[0035] 10…Cushioning material, 11…Bending part, 12…Side end part, 13…Upper end part, 14…Lower end part, 15…Final stitching part, 20, 20A, 20B…Fiber laminate, 21, 22…Parts, 22a, 22b…Parts, 23 - 27…Parts, 30…Polyester fiber, 31…Tip, F…Opening, S…Stitching part.

Claims

1. Two rectangular fiber laminates formed in a mesh shape by resin fibers, with a part of their outer peripheral portions left as an opening after being sewn together with the outer peripheral portions melted by heat treatment, and turned inside out to form a three-dimensional structure in a bag shape, and A cushioning material, characterized in that it is located at the opening and has a final sewing portion formed by sewing.

2. The cushioning material according to claim 1, characterized in that the mesh shape is formed by a Raschel weave.

3. The cushioning material according to claim 1, characterized in that a functional member having functionality is accommodated inside the three-dimensional structure in a bag shape.

4. Melting the outer peripheral portion of a single rectangular fiber laminate formed in a mesh shape by resin fibers by heat treatment, Bending the fiber laminate at the center, Sewing with a part of its outer peripheral portion left as an opening, Pulling out the inside of the fiber laminate from the opening, turning it inside out, A method for assembling a cushioning material, characterized by sewing the opening.

5. Melting the outer peripheral portions of two rectangular fiber laminates formed in a mesh shape by resin fibers by heat treatment, Stacking the fiber laminates, Sewing with a part of their outer peripheral portions left as an opening, Pulling out the inside of the fiber laminates from the opening, turning them inside out, A method for assembling a cushioning material, characterized by sewing the opening.

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