Pocket coil

Abstract

To provide a pocket coil provided with a cutting line by which breakage unexpectedly caused when a mattress is manufactured or used hardly spreads.SOLUTION: The pocket coil 100 includes a bag body 10 in which a large number of coil spring housing chambers 2 are arranged in a row, and a large number of coil springs 3 housed one by one in the coil spring housing chambers 2. The bag body 10 has a longitudinal fusion-bonding line 5 formed in the longitudinal direction of the pocket coil 100 by fusion-bonding side walls at both end portions in the widthwise direction of the belt-shaped nonwoven fabric 1, a partition fusion-bonding line 6 partitioning the adjacent coil spring accommodating chambers 2, 2, an upper 11a 12 and a lower 11b 13 covering both ends in the axial direction of the coil spring 3, and side walls 14 covering the sides of the coil spring 2. The bag body 10 has a cutting line 4 consisting of a wavy broken line extending in the longitudinal direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This invention relates to so-called pocket coils that are loaded inside mattresses, and more particularly to pocket coils that have a nonwoven fabric bag body loaded with a coil spring and have cutting lines for disassembly. [Background technology]

[0002] In the past, in order to recycle the nonwoven fabric of pocket coils and coil springs from discarded mattresses, it has been proposed to provide perforations or the like in the nonwoven fabric to make it easier to dismantle the pocket coils (see Patent Documents 1 to 3).

[0003] For example, Patent Document 1 proposes a pocket coil in which perforations are made in the upper and lower walls of a bag that houses the coils, along the direction in which the coils are arranged. In the pocket coil of Patent Document 1, perforations are provided on the top and bottom walls of the bag body to prevent the force caused by the expansion and contraction of the coil spring from being applied to the perforations when the mattress is in use.

[0004] In response to this, Patent Document 2 proposes a pocket coil with perforations along the periphery of the pouch that houses the coil spring. The pocket coil in Patent Document 2 is configured so that the pouch ruptures when the pouch is peeled off, by adhering the top and bottom walls of the pouch to the mattress outer cover.

[0005] However, in the pocket coil of Patent Document 2, the coil springs are housed individually in a cylindrically shaped bag body, so if the perforations in some of the bags stop breaking, there is a risk that all of the perforations will not be able to break at the same time.

[0006] Therefore, in Patent Document 3, multiple pocket spaces lined up in a row are formed from a single piece of fabric, and continuous perforations are provided on both sides of the pocket spaces in the direction in which the pocket spaces are lined up, so that the perforations can be broken continuously. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-65726 [Patent Document 2] Japanese Patent Application Laid-Open No. 2012-95785 [Patent Document 3] Japanese Patent Publication No. 2022-180052 Summary of the Invention [Problem to be solved by the invention]

[0008] However, because the pocket coil in Patent Document 3 has continuous, linear perforations, if an external force is applied during the manufacture or use of the mattress and the perforations of the pocket coil suddenly break, the break will spread along the perforation, which is a problem. The present invention was made in light of the above problem, and aims to provide a pocket coil with a cutting line that prevents the spread of unexpected breaks that occur during the manufacture or use of the mattress. [Means for solving the problem]

[0009] The invention made to solve the above problems is a pocket coil to be placed inside a mattress, comprising a bag body in which a number of coil spring storage chambers are arranged in a row, and a number of coil springs stored one by one in the coil spring storage chambers, the bag body being formed from a strip-shaped nonwoven fabric and having a longitudinal fusion line formed in the longitudinal direction of the pocket coil by fusing both widthwise ends of the nonwoven fabric, a partition fusion line that is perpendicular to the longitudinal fusion line and separates adjacent coil spring storage chambers, an upper wall and a lower wall that cover both axial ends of the coil spring, and side walls that cover the sides of the coil spring, the coil spring being stored in the coil spring storage chamber with the axial direction aligned with the partition fusion line, and the bag body having a cutting line consisting of a wavy dashed line extending in the longitudinal direction.

[0010] The pocket coil of the present invention has a wavy cutting line, so that any breaks that occur along the cutting line when the mattress is in use, etc., can be prevented from progressing along the cutting line.

[0011] The cutting lines are preferably provided on both side walls of the bag, so that when dismantling the mattress, the bag can be easily opened and the coil spring can be removed simply by pulling the top wall of the bag upward.

[0012] The cut lines on both side walls of the bag are preferably arranged asymmetrically on either side of the bag, thereby preventing the cut lines on both side walls of the bag from breaking simultaneously when the mattress is in use, etc.

[0013] The cutting line preferably has discontinuous portions spaced at intervals wider than the intervals between the short lines that make up the dashed line, so that the discontinuous portions can prevent the propagation of breaks that may occur unexpectedly in the cutting line.

[0014] It is preferable that the cutting lines of both side walls have discontinuities, and the positions of the discontinuities on the cutting lines of both side walls are different in the longitudinal direction. This prevents the spread of any unexpected breaks that occur on either of the cutting lines of both side walls. Furthermore, when the outer cover attached to the upper wall of the bag is pulled to tear the bag along the cutting lines, the breaks on both cutting lines are prevented from reaching the discontinuities at the same time, thereby preventing the break from being stopped by the discontinuities.

[0015] The discontinuous portions are preferably provided at the crests of the waves or the bottoms of the valleys of the cutting line. Since a covering member that forms the upper or lower surface of the mattress is attached to the upper or lower wall of the pocket coil, providing discontinuous portions at the crests of the waves or the bottoms of the valleys of the wavy cutting line that are closest to the covering member and that will be subjected to the most force when the mattress is in use can prevent the cutting line from breaking unexpectedly when the mattress is in use.

[0016] The cutting line may be provided so as to straddle the side wall and the upper wall, or the side wall and the lower wall, of the bag body, thereby preventing the spread of an unexpected breakage that occurs in the cutting line when the cutting line straddles the upper wall, the side wall, and the lower wall.

[0017] It is preferable that the partition fusion line has a non-fused portion and the cutting line passes through the non-fused portion, thereby preventing the cutting line from becoming hard at the intersection with the fused portion of the partition fusion line, making it difficult to cut along the cutting line.

[0018] The present invention includes a pocket coil in which the cutting lines are curved, triangular, or rectangular. [Effects of the Invention]

[0019] As described above, according to the pocket coil of the present invention, the cutting line can be prevented from accidentally breaking during manufacturing or use. [Brief explanation of the drawings]

[0020] [Figure 1] 1 is a perspective view showing a pocket coil according to a first embodiment of the present invention. FIG. [Figure 2] FIG. 2 is a partially transparent side view of the pocket coil of FIG. 1. [Figure 3] FIG. 2 is a front view of the pocket coil of FIG. 1. [Figure 4] FIG. 10 is a perspective view showing a pocket coil according to a second embodiment of the present invention. [Figure 5] FIG. 5 is a partially transparent side view of the pocket coil of FIG. 4. [Figure 6] FIG. 10 is a perspective view showing a pocket coil according to a third embodiment of the present invention. [Figure 7] FIG. 7 is a plan view of the pocket coil of FIG. 6. [Figure 8] FIG. 4 is an explanatory diagram of a discontinuous portion in a cutting line according to the first embodiment. [Figure 9]1A is a schematic front view showing another example of longitudinal fusion lines provided in the side walls of the pocket coil of the present invention, and FIG. 1B is an enlarged view of part A in FIG. 1A. [Figure 10] 10A is a schematic front view showing another example of longitudinal fusion lines provided in the side walls of the pocket coil of the present invention, and FIG. 10B is an enlarged view of part B in FIG. [Figure 11] 1A, 1B, and 1C are partial schematic front views, partial schematic side views, and plan views, respectively, showing another example of longitudinal fusion lines provided in the upper wall of the pocket coil of the present invention. [Figure 12] 10A, 10B, and 10C are a front view, a side view, and a plan view, respectively, showing another example of a longitudinal fusion line provided in the upper wall of the pocket coil of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0021] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings, however, the present invention is not limited to the following embodiments.

[0022] (First embodiment) 1 to 3 show a pocket coil 100 according to a first embodiment of the present invention. As shown in Fig. 1, the pocket coil 100 comprises a bag body 10 that houses coil springs and a number of coil springs 3, 3, 3..., and is installed as cushioning material in a mattress placed on a bed or the like. The pocket coil 100 of the present invention has cutting lines 4 on the bag body 10 to facilitate disassembly for recycling.

[0023] The bag body 10 is formed from a strip-shaped nonwoven fabric 1, and has two broken longitudinal fusion lines 5, 5 that overlap and fusion-bond both widthwise end portions 11 a, 11 b of the nonwoven fabric 1, a number of broken partition fusion lines 6, 6, ... that intersect at right angles to the longitudinal fusion lines 5, 5, and a number of coil spring accommodating chambers 2, 2, ... that are partitioned by the partition fusion lines 6, 6, ... (see Figure 2). The nonwoven fabric 1 used for the bag body 10 is not particularly limited as long as it can be fused by ultrasonic waves, high frequency waves, lasers, or other known fusion methods.

[0024] Each of the coil spring accommodating chambers 2 accommodates one coil spring 3 in the same axial direction as the partition fusion wires 6 . The bag body 10 has an upper wall 12 and a lower wall 13 that cover both axial ends of the coil spring 3, and side walls 14, 14 that cover the left and right sides of the coil spring 3 (left and right in FIG. 3). The material of the coil spring 3 is not particularly limited, and a metal spring such as stainless steel or spring steel may be used, or a resin spring such as carbon fiber or plastic may also be used.

[0025] 2, the bag body 10 is formed by folding the widthwise opposite ends 11a, 11b of the strip-shaped nonwoven fabric 1 so that they overlap on one of the side walls 14 and ultrasonically fusing them together to form two parallel broken longitudinal fusion lines 5, 5. The longitudinal fusion lines 5, 5 are provided so as to pass through one of the left and right side walls 14.

[0026] However, the number of longitudinal fusion lines 5 in the present invention is not limited to two, and may be one, three or more, and may be a continuous solid line. Furthermore, as shown in Fig. 9, longitudinal fusion lines 5 may be provided by reversing the inside and outside of widthwise ends 11a, 11b of nonwoven fabric 1. As shown in Fig. 10, widthwise ends 11a, 11b of nonwoven fabric 1 may be aligned, and longitudinal fusion lines 5 may be provided at position 11d at the bases of band-shaped connecting margins 11c, 11c, and connecting margins 11c, 11c may then be folded.

[0027] Alternatively, the longitudinal fusion lines 5 may be provided on the upper wall 12 of the bag body 10. As in the example of Fig. 11, the inner surfaces of widthwise end portions 11a, 11b of the nonwoven fabric 10 may be overlapped back to back, and the longitudinal fusion lines 5 may be provided on a band-like connecting tab 11c suspended from the upper surface 12 of the bag body 10. Furthermore, as in the example of Fig. 12, the widthwise end portions 11a, 11b of the nonwoven fabric 1 may be overlapped horizontally one above the other, and the longitudinal fusion lines 5 may be provided.

[0028] As shown in FIG. 2, the partition fusion line 6 extends vertically and perpendicular to the longitudinal fusion lines 5, 5. In this embodiment, the partition fusion line 6 is a broken line in which rectangular fused portions 6a, 6a, ... are arranged at intervals, but it may also be arranged as a continuous straight line. The upper and lower ends of the partition fusion line 6 have gussets 71, 71 formed by folding the upper wall 12 or the lower wall 13 inward and sandwiching it between the left and right side walls 14, 14, thereby forming a total of four layers of nonwoven fabric that are fused together. The partition fusion line 6 also has a non-fused portion 61 in the vertical direction where there is no fused portion 6a.

[0029] 1 and 2, the cutting lines 4 are sinusoidal (curved wave) and broken lines. Two cutting lines 4 are provided, one on each of the left and right side walls 14, 14 (on the rear side of the front side in FIG. 2) along the longitudinal direction of the bag body 10. In this embodiment, the left and right cutting lines 4, 4 have different positions of peaks and valleys in the longitudinal direction (left and right direction in FIG. 2).

[0030] In the example of Figure 2, the cutting lines 4 are provided above the longitudinal fusion lines 5,5 on the side wall 14, but they may also be provided below the longitudinal fusion lines 5,5, or two lines may be provided, one above and one below the longitudinal fusion lines 5,5, or three or more lines may also be provided.

[0031] In this embodiment, the cutting line 4 is a line melted by ultrasonic waves or the like and does not penetrate the nonwoven fabric 1. This prevents insects such as bedbugs and mites, and dust such as house ducts, allergens, and mold from entering the bag 10 through the cutting line 4. However, the cutting line 4 may also be a so-called perforation, which is a series of slits or through-holes that penetrate the nonwoven fabric 1 in a broken line.

[0032] In the illustrated example, the cutting line 4 is formed of a sine curve, but is not limited to this and may be formed in other curved, triangular, or rectangular waves. The amplitude and pitch of the wave of the cutting line 4 may be constant, or may vary depending on the position in the longitudinal direction.

[0033] As shown in Figure 8, the cutting line 4 has discontinuous portions 4a at the crests 4b of the mountains, with a spacing D wider than the spacing d between the dashed lines of the cutting line 4. By providing the discontinuous portions 4a at the crests 4b of the cutting line 4 that are closest to the upper wall 12 that is attached to the surface layer member, such as the urethane foam, sheet, or quilted panel, of the mattress when the pocket coil 100 is incorporated into the mattress, it is possible to prevent the cutting line 4 from accidentally breaking during use of the mattress. If the cutting line 4 is located closer to the lower wall 13 than the upper wall 12, it is preferable to provide the discontinuous portions 4a at the bottoms 4c of the valleys of the cutting line 4 that are closest to the lower wall 13. However, the discontinuous portions 4a may be located in locations other than the crests 4b and bottoms 4c.

[0034] As shown in FIG. 8 , the cutting line 4 is provided so as to pass through the non-fused portion 61 of the partition fusion line 6. The non-fused portion 61 is made up of a portion of the nonwoven fabric that is not fused along the partition fusion line 6. When the fused portions of the cutting line 4 and the partition fusion line 6 intersect, the intersecting portion becomes hard, making it difficult to cut along the cutting line 4. In this way, the cutting line 4 passes through the non-fused portion 61 of the partition fusion line 6, allowing the bag body 10 to be smoothly cut and disassembled along the cutting line 4.

[0035] The non-fused portion 61 is preferably larger than the wave height h (twice the amplitude) of the cutting line 4. This prevents the cutting line 4 from intersecting the fused portion 6a of the partition fusion line 6 even if the pitch at which the coil spring accommodating chambers 2 are arranged differs from the wave pitch of the cutting line 4.

[0036] When disassembling the pocket coil 100, the covering such as urethane foam bonded to the top wall 12 of the pocket coil 100 is lifted up so as to peel it off from the pocket coil 100. This causes the urethane foam to pull the top wall 12 of the pocket coil 100, cutting and releasing the pouch 10 along the cutting lines 4, 4 on both side walls 14, 14 of the pocket coil 100. After that, the coil spring 3 is removed from the inside, and the coil spring 3 and pouch 10 (nonwoven fabric 1) are separated. In this way, since the tear lines 4 are provided on both side walls 14, 14 of the bag body 10, the bag body 10 can be disassembled simply by pulling the top wall 12 upward.

[0037] (Actions and Effects) As described above, the pocket coil 100 according to the first embodiment provides the following functions and effects. (1) Since the cutting line 4 is formed in a wavy line, a break that occurs in the cutting line 4 when the mattress is in use can be prevented from progressing along the cutting line 4. (2) Since the cutting lines 4 are provided on both side walls of the bag body 10, the bag body 10 can be easily opened and the coil spring can be removed simply by pulling the upper wall 12 of the bag body 10 upward. (3) The cutting lines 4, 4 on both side walls 14, 14 of the bag body 10 are arranged asymmetrically across the bag body 10, so that simultaneous rupture of the cutting lines 4, 4 on both side walls 14, 14 can be prevented when the mattress is in use, etc. (4) The discontinuous portion 4a is provided in the cutting line 4, so that the propagation of the fractured portion occurring in the cutting line 4 can be suppressed by the discontinuous portion 4a. (5) When tearing the top wall 12 of the bag body 10 along the cutting lines 4, 4, if the breaking points of both cutting lines 4, 4 reach the discontinuous parts 4a, 4a at the same time, the progress of the cutting may be hindered. In the first embodiment, the positions of the discontinuous parts 4a, 4a of the cutting lines 4, 4 on the left and right side walls 14, 14 in the longitudinal direction of the bag body 10 are different on both side walls, so that the breaking points of the cutting lines 4, 4 are prevented from reaching the discontinuous parts 4a, 4a at the same time, making it easier to cut the cutting lines 4, 4 when disassembling the bag body 10. (6) The discontinuous portion 4a is provided at the crest 4b of the wave or the bottom 4c of the valley in the cutting line 4, so that the cutting line 4 can be effectively prevented from breaking unexpectedly when the mattress is in use. (7) The cutting lines 4, 4 pass through the non-fused portions 61 of the partition fusion lines 6, so that the cutting lines 4, 4 do not harden at the intersections with the partition fusion lines 6, making cutting difficult.

[0038] (Second embodiment) 4 and 5 show a pocket coil 200 according to a second embodiment of the present invention. As shown in FIG. 5, in the pocket coil 200, the lower end of the partition fusion line 206 extends to the lower wall 13 of the bag body 10, as in the first embodiment, while the upper end of the partition fusion line 206 does not reach the upper wall 12 of the bag body 10. Instead, the partition fusion line 206 has an annular non-fused portion 261 that spans both side walls 14, 14 and the upper wall 12, as shown in FIG. 4. As a result, the gusset 71 of the coil spring accommodating chamber 2 is not formed on the upper wall 12 side of the bag body 10, but is provided only on the lower wall 13 side. The pocket coil 200 has two parallel wavy and dashed cutting lines 204, 204 that extend longitudinally through the upper wall 12 of the bag body 10. The cutting lines 204 are formed by fusion lines using ultrasound or the like, and do not penetrate the nonwoven fabric 1.

[0039] In this way, two parallel cutting lines are provided on the upper wall 12, and by pulling the portion between the two cutting lines 204, 204, all of the coil spring accommodating chambers 2 can be successively disassembled. Also, in the pocket coil 200, the cutting lines 204, 204 pass through the non-fused portion 261 of the partition fusion line 206, so that the cutting is not hindered by the partition fusion line 206. In the second and subsequent embodiments, parts and members that are common to the other embodiments and have already been described are given the same reference numerals and description thereof will be omitted.

[0040] (Third embodiment) Next, a pocket coil 300 according to a third embodiment of the present invention will be described using Figures 6 and 7. The pocket coil 300 has the same partition fusion line 206 as in the second embodiment, and is provided with an annular non-fused portion 261 that spans both side walls 14, 14 and the top wall 12. In the pocket coil 300 according to the third embodiment, wavy cutting lines 304, 304 are provided so as to pass through the non-fused portion 261 and to span the side walls 14 and top wall 12 of the bag body 10.

[0041] In this way, by having the cutting line 304 straddle the side wall 14 and the top wall 12, any breakage that may occur unexpectedly at the cutting line 304 in the side wall 14 due to use of the mattress or the like is prevented from spreading due to the top wall 12 being attached to the covering. Furthermore, when dismantling the pocket coil 300, all of the coil spring accommodating chambers 2 can be successively disassembled by pulling the portion between the two cutting lines 304, 304. Furthermore, in the pocket coil 300, the cutting lines 304, 304 pass through the non-fused portion 261 of the partition fusion line 206, so that the cutting is not hindered by the partition fusion line 206.

[0042] As described above, the pocket coil of the present invention is not limited to the above-described embodiment. For example, the cutting line may be provided on the lower wall of the bag body, or may be provided so as to span the side wall and the lower wall. Furthermore, the cutting line may be provided on one of the upper wall, lower wall, and side wall of the bag body, or on some or all of them. Any number of cutting lines, including one or more, may be provided on one of the upper wall, lower wall, and side wall. The cutting lines on both side walls may be provided symmetrically across the bag body, and the discontinuous portions may be located at the same positions along the length of the bag body. The cutting line may not have a discontinuous portion, or the discontinuous portion may be located at a position other than the crest or bottom of the trough of the cutting line. The partition fusion line may not have a non-fused portion, and the cutting line may intersect with the fused portion of the partition fusion line. The bag body may have a longitudinal fusion line, which is a seam in the width direction of the nonwoven fabric, on the upper or lower wall, and may have no non-fusion portion, or may have non-fusion portions on both sides above and below the partition fusion line. The cutting line is not limited to a sinusoidal or curved wavy line, but may also be a triangular or rectangular wave. The cutting line is not limited to a fusion line, but may also be a perforation consisting of multiple slits that penetrate the nonwoven fabric. [Explanation of symbols]

[0043] 100, 200, 300 pocket coils 10 Bag body 1. Nonwoven fabric 1a, 1b Both ends of the nonwoven fabric in the width direction 12 Upper wall 13 Lower wall 14 Side wall 2 Coil Spring Containment Chamber 3 Coil springs 4,204,304 Cutting line 4a Discontinuity 4b The top of the mountain 4c Bottom of the Valley 5 Longitudinal fusion line 6 Partition fusion line 61 Non-fused part

Claims

1. A pocket coil installed in a mattress, a bag body in which a number of coil spring accommodating chambers are arranged in a row; a number of coil springs accommodated one by one in the coil spring accommodation chambers; Equipped with The bag body is formed from a strip-shaped nonwoven fabric, and has a longitudinal fusion line formed in the longitudinal direction of the pocket coil by fusing both widthwise ends of the nonwoven fabric, a partition fusion line that is perpendicular to the longitudinal fusion line and separates adjacent coil spring accommodating chambers, an upper wall and a lower wall that cover both axial ends of the coil spring, and side walls that cover the sides of the coil spring, The coil spring is accommodated in the coil spring accommodating chamber in the same axial direction as the partition fusion line, A pocket coil characterized in that the bag body has a cutting line consisting of a wavy broken line extending in the longitudinal direction.

2. The pocket coil according to claim 1 , wherein the cutting lines are provided on both side walls of the bag body.

3. The pocket coil according to claim 2, wherein the cutting lines provided on both side walls of the bag body are provided asymmetrically on either side of the bag body.

4. 3. The pocket coil according to claim 1, wherein the cutting line has discontinuous portions spaced apart at intervals wider than the intervals between the multiple short lines that make up the dashed line.

5. The cutting lines on both side walls have discontinuities, The pocket coil according to claim 2, wherein the cutting lines of the both side walls have discontinuous portions at different positions in the longitudinal direction.

6. The pocket coil according to claim 4, wherein the discontinuous portion is provided at the top of a crest or the bottom of a valley of a wave in the cutting line.

7. 3. The pocket coil according to claim 1, wherein the cutting line is provided so as to straddle the side wall and the upper wall of the bag body, or the side wall and the lower wall.

8. The pocket coil according to claim 1 or 2, wherein the partition fusion line has a non-fused portion, and the cutting line passes through the non-fused portion.

9. The pocket coil according to claim 1 or claim 2, wherein the cutting lines are curved, triangular, or rectangular.

Images