Manufacturing method for bedding covers

Abstract

The present invention provides a bedding cover that prevents the core material from shifting and allows for easy insertion and removal of the core material. [Solution] A method for manufacturing a bedding cover according to one embodiment includes the steps of: applying a napping process to the upper surface of the lining 22 and the lower surface of the outer fabric 21; applying a resin coating to the napped upper surface of the lining 22 and the napped lower surface of the outer fabric 21, thereby applying a resin coating to the lining 22 and the outer fabric 21, respectively; sewing a zipper 40 to the outer fabric 21; overlapping the lower surface of the outer fabric 21 with the upper surface of the lining 22 in a third direction D3; and sewing together the outer edges 22j of the lining 22 and the outer edges 21j of the outer fabric 21.

Description

[[TECHNICAL FIELD]]

[0001] The present disclosure relates to a method for manufacturing a bedding cover that accommodates a core material of bedding. [[BACKGROUND ART]]

[0002] Patent Document 1 describes a bedding cover that accommodates a three-dimensional network structure. The bedding cover includes a fiber cover having a fastener on a side surface. In a plan view, the fiber cover has a rectangular shape. By opening and closing the fastener, the three-dimensional network structure can be put into and taken out from the inside of the bedding cover. One fastener extends along the long side of the fiber cover in a plan view. [[PRIOR ART DOCUMENT]] [[PATENT DOCUMENT]]

[0003] [[Patent Document 1]] Japanese Unexamined Patent Publication No. 2020-36843 [[SUMMARY OF THE INVENTION]] [[Problem to be Solved by the Invention]]

[0004] When bedding is used with a core material placed inside a bedding cover, the core material may shift inside the bedding cover. If the core material shifts inside the bedding cover, it may cause discomfort to the user of the bedding. In order to prevent the core material from shifting inside the bedding cover, a string-shaped member for fixing the core member is sometimes provided inside the bedding cover. However, in this case, when putting the core material into or taking the core material out of the bedding cover, it is necessary to perform operations of fixing the core material to the string-shaped member and detaching the core material from the string-shaped member, which causes a problem that the core material cannot be put in and taken out easily.

[0005] In the aforementioned bedding cover, one zipper extends along the long side of the fabric cover in a plan view. Therefore, when inserting or removing the core material from the bedding cover, it may be necessary to reach deep inside the cover, which can make it difficult to easily insert or remove the core material. Consequently, there is a need to prevent the core material from shifting inside the bedding cover while also making it easy to insert and remove the core material.

[0006] The purpose of this disclosure is to provide a bedding cover that can prevent the core material from shifting and allows for easy insertion and removal of the core material. [Means for solving the problem]

[0007] (1) The method for manufacturing a bedding cover according to the present disclosure comprises a lining having a first long side extending in a first direction and a first short side extending in a second direction which intersects the first direction, and an outer fabric having a second long side extending in a first direction and a second short side extending in a second direction, and being superimposed on the lining in a third direction which intersects the first and second directions. The manufacturing method comprises the steps of: applying a napping process to the upper surface of the lining and the lower surface of the outer fabric, respectively; applying a resin coating to the napped upper surface of the lining and the napped lower surface of the outer fabric, respectively; sewing a zipper onto the outer fabric; superimposing the lower surface of the outer fabric onto the upper surface of the lining in a third direction; and sewing the outer edges of the lining and the outer edges of the outer fabric together.

[0008] This method for manufacturing a bedding cover produces a bedding cover having a lining that extends in a first and second direction, and an outer fabric that is layered on top of the lining in a third direction. The upper surface of the lining and the lower surface of the outer fabric are each subjected to a napping process. The napping process makes the upper surface of the lining and the lower surface of the outer fabric fluffy. The upper surface of the lining and the lower surface of the outer fabric are each subjected to a resin coating. By applying resin to the fluffy upper surface of the lining and the lower surface of the outer fabric, the fabric becomes less slippery and has a good feel against the skin. In this bedding cover, the upper surface of the lining and the lower surface of the outer fabric are fluffy and made less slippery, so the slippage of the core material when it is inserted inside the bedding cover, that is, between the upper surface of the lining and the lower surface of the outer fabric, can be prevented. Therefore, since there is no need to provide a string-like member to secure the core material inside the bedding cover, the work of securing the core material to the string-like member and the work of removing the core material from the string-like member are eliminated, making it easy to insert and remove the core material. Furthermore, this bedding cover has a linear zipper sewn onto the outer fabric that faces vertically upward. Therefore, by opening and closing the linear zipper sewn onto the outer fabric, it is possible to further easily insert and remove the core material from the bedding cover.

[0009] (2) In (1) above, the lining may be rectangular in shape having a pair of first long sides and a pair of first short sides, and the outer fabric may be rectangular in shape having a pair of second long sides and a pair of second short sides. In the process of sewing the zipper onto the outer fabric, the zipper may be sewn onto the outer fabric such that the zipper, having a length equal to or greater than the length of the second long side, extends diagonally with respect to the first and second directions. In this case, the zipper on the outer fabric has a length equal to or greater than the second long side of the outer fabric and extends diagonally with respect to the first and second directions. Because the zipper, having a length equal to or greater than the second long side, extends diagonally with respect to the first and second directions, it is possible to easily put a hand inside the open zipper, making it even easier to insert and remove the core material into the bedding cover.

[0010] (3) In (2) above, the first end of the zipper may be located in a second direction from a first reference line that passes through the center of the outer fabric and extends in a first direction, and in a first direction from a second reference line that passes through the center and extends in a second direction. The second end of the zipper, opposite to the first end, may be located in a direction opposite to the second direction from the first reference line, and in a direction opposite to the first direction from the second reference line. In the process of sewing the outer edges together, multiple openings may be formed in the outer edge of the lining, which are parts where the outer edge of the outer fabric is not sewn together. The openings may be formed at the ends of the first and second long sides located at the ends in the second direction opposite to the first direction, and at the ends of the first and second long sides located at the ends opposite to the second direction. In this case, an opening in the bedding cover is formed at the end opposite to the first end of the zipper when viewed from the first reference line, and at the end opposite to the second end of the zipper when viewed from the first reference line. By forming an opening at a position away from the main zipper in a second direction, it is possible to reach a hand through the opening into the bedding cover and pull the core material into the bedding cover. Therefore, it is possible to insert the core material into the bedding cover more easily.

[0011] (4) In (1) above, the lining may be rectangular in shape having a pair of first long sides and a pair of first short sides, and the outer fabric may be rectangular in shape having a pair of second long sides and a pair of second short sides. In the process of sewing the zipper onto the outer fabric, the zipper may be sewn onto the outer fabric so that it extends in the first direction. In this case, the zipper is sewn so that it extends along the first and second long sides. Therefore, the length of the zipper sewn onto the outer fabric can be secured, making it easier to insert and remove the core material into the bedding cover. [Effects of the Invention]

[0012] According to this disclosure, the core material can be made less likely to shift, and the core material can be easily inserted and removed. [Brief explanation of the drawing]

[0013] [Figure 1] Figure 1 is a perspective view showing a bedding cover according to an embodiment. [Figure 2] Figure 2 is a view of the bedding cover from Figure 1, seen from above. [Figure 3] Figure 3 is a cross-sectional view taken along line AA in Figure 2. [Figure 4] Figure 4 is a schematic cross-sectional view showing the fabric of a bedding cover. [Figure 5] Figure 5 is a flowchart showing an example of the manufacturing process for the dough shown in Figure 4. [Figure 6] Figure 6 schematically shows the state in which the fabric is immersed in liquid resin. [Figure 7] Figures 7(a) and 7(b) show modified versions of the bedding cover. [Figure 8] Figures 8(a) and 8(b) show bedding covers according to modified examples. [Modes for carrying out the invention]

[0014] The embodiments of the bedding cover according to this disclosure will be described below with reference to the drawings. In the description of the drawings, the same or equivalent elements are denoted by the same reference numerals, and redundant explanations are omitted as appropriate. Some illustrations in the drawings may be simplified or exaggerated for ease of understanding, and dimensional ratios, etc., are not limited to those shown in the drawings.

[0015] Figure 1 shows an example of bedding 1 equipped with a bedding cover 10 according to this embodiment. Bedding 1 is a comforter. Comforter is bedding that is placed over a person's body, and is, for example, a comforter or a towel blanket. Comforter may be a thin comforter or a quilted blanket. The bedding cover is a cover that covers the core material of the bedding. The bedding cover is, for example, a comforter cover, a fitted sheet cover, or a pillowcase. As an example, bedding 1 is a comforter used in a state where it is placed on a fitted sheet C which is placed on a bed B.

[0016] Fig. 2 is a plan view schematically showing the bedding 1. As shown in Fig. 1 and Fig. 2, the bedding 1 extends along a first direction D1 and a second direction D2 intersecting the first direction D1, and has a thickness in a third direction D3 intersecting the first direction D1 and the second direction D2. For example, the first direction D1 is a direction from the foot portion to the head of the user's body when using the bedding 1, and the second direction D2 is the width direction of the bedding 1 in a plan view. For example, the third direction D3 is vertically downward.

[0017] Fig. 3 is a cross-sectional view taken along line A-A of Fig. 2. As shown in Fig. 2 and Fig. 3, the bedding 1 includes two pieces of fabric 20. As an example, the bedding cover 10 is a duvet cover. The two pieces of fabric 20 are a surface fabric 21 and a lining fabric 22 opposite to the surface fabric 21 in the third direction D3. In a plan view (when viewed along the third direction D3), the surface fabric 21 and the lining fabric 22 are rectangular.

[0018] A part of an outer edge 21j of the surface fabric 21 and a part of an outer edge 22j of the lining fabric 22 are sewn together with a thread 23. The outer edge 21j is a portion including a frame-shaped part formed by a second long side 21b, a second short side 21c, a second long side 21d and a second short side 21f which will be described in detail later. Similarly, the outer edge 22j is a portion including a frame-shaped part formed by a first long side 22b, a first short side 22c, a first long side 22d and a first short side 22f.

[0019] As an example, the surface fabric 21 and the lining fabric 22 are cloth. The surface fabric 21 and the lining fabric 22 are, for example, thin fabrics used as a duvet cover. The surface fabric 21 is a fabric located above the lining fabric 22, and in the bedding 1, a core material 2 is accommodated inside the bedding cover 10 (between the surface fabric 21 and the lining fabric 22). The core material 2 can be put into and taken out of the bedding cover 10. For example, the core material 2 is a bedding main body (duvet main body). The core material 2 is constituted of, for example, fibers and cloth.

[0020] For example, the bedding cover 10 does not have a string-like member to secure the core material 2 located inside the bedding cover 10 to the bedding cover 10. Conventional bedding covers were provided with a loop-shaped string-like member called a tie to secure the core material located inside the bedding cover to the bedding cover. In contrast, the bedding cover 10 is made of a non-slip fabric 20 (outer fabric 21 and inner fabric 22), so the slipping and shifting of the core material 2 inside the bedding cover 10 can be suppressed even without a string-like member such as a tie. Therefore, the bedding cover 10 does not have a string-like member to secure the core material 2 inside the bedding cover 10.

[0021] The outer fabric 21 has second long sides 21b, 21d extending in a first direction D1, and second short sides 21c, 21f extending in a second direction D2, and is overlapped with the lining 22 in a third direction D3. The outer fabric 21 has, for example, a second long side 21b extending in a first direction D1, and a second short side 21c extending in a second direction D2 from one end of the second long side 21b.

[0022] The outer fabric 21 has a second long side 21d extending in the first direction D1 from the end of the second short side 21c opposite to the second long side 21b, and a second short side 21f extending in the direction opposite to the second direction D2 from the end of the second long side 21d opposite to the second short side 21c. The second long side 21b is located at one end of the outer fabric 21 in the second direction D2, and the second long side 21d is located at the other end of the outer fabric 21 in the second direction D2.

[0023] The lining 22 has first long sides 22b, 22d extending in a first direction D1, and first short sides 22c, 22f extending in a second direction D2. The lining 22 has a first long side 22b that is opposite to the second long side 21b of the outer fabric 21 along the third direction D3, and a first short side 22c that is opposite to the second short side 21c of the outer fabric 21 along the third direction D3.

[0024] The lining 22 has a first long side 22d that is opposite to the second long side 21d of the outer fabric 21 along the third direction D3, and a first short side 22f that is opposite to the second short side 21f of the outer fabric 21 along the third direction D3. For example, the outer fabric 21 and the lining 22 have the same shape and the same size as each other.

[0025] The outer fabric 21 has an upper surface 21g extending in the first direction D1 and the second direction D2, and a lower surface 21h opposite to the upper surface 21g. The lining 22 has a lower surface 22g extending in the first direction D1 and the second direction D2, and an upper surface 22h opposite to the lower surface 22g. For example, in the bedding 1, the lower surface 21h of the outer fabric 21 and the upper surface 22h of the lining 22 are surfaces facing the core material 2, while the upper surface 21g of the outer fabric 21 and the lower surface 22g of the lining 22 are surfaces facing away from the core material 2. The lower surface 21h and the upper surface 22h are the inner surfaces of the bedding cover 10, and the upper surface 21g and the lower surface 22g are the outer surfaces of the bedding cover 10.

[0026] In the outer fabric 21, the coefficient of friction of the lower surface 21h (for example, the coefficient of static friction) is greater than that of the upper surface 21g. The lower surface 21h is fluffier than the upper surface 21g. In the lining 22, similar to the outer fabric 21, the coefficient of friction of the upper surface 22h is greater than that of the lower surface 22g, and the upper surface 22h is fluffier than the lower surface 22g. The lower surface 21h is less slippery than the upper surface 21g, and the upper surface 22h is less slippery than the lower surface 22g. As a result, the inner surface of the bedding cover 10 is less slippery than the outer surface of the bedding cover 10.

[0027] The bedding cover 10 has a zipper 40 for inserting and removing the core material 2 into the bedding cover 10. The zipper 40 is sewn to the outer fabric 21. For example, the zipper 40 is made of resin. However, the material of the zipper 40 is not particularly limited. The zipper 40 has a pair of elements 41 and a slider 42 for opening and closing the pair of elements 41.

[0028] For example, when the slider 42 moves to the first end 40A of the zipper 40, the zipper 40 (a pair of elements 41) is opened, and when the slider 42 moves to the second end 40B opposite to the first end 40A of the zipper 40, the zipper 40 is closed. With the zipper 40 open, the core material 2 can be inserted into and removed from the inside of the bedding cover 10.

[0029] The linear fastener 40 has a length equal to or greater than the length of the second long side 21b. For example, the length of the linear fastener 40 is 210 cm or more and 270 cm or less. The linear fastener 40 extends diagonally with respect to the first direction D1 and the second direction D2. The first end 40A of the linear fastener 40 is located in the second direction D2 relative to the first reference line L1 which passes through the center O of the outer fabric 21 and extends along the first direction D1, and in the first direction D1 relative to the second reference line L2 which passes through the center O and extends along the second direction D2. The second end 40B of the linear fastener 40 is located in the direction opposite to the second direction D2 relative to the first reference line L1, and in the direction opposite to the first direction D1 relative to the second reference line L2.

[0030] For example, the outer fabric 21 has a first corner C1 at the intersection of the second long side 21d and the second short side 21f, a second corner C2 at the intersection of the second long side 21b and the second short side 21c, a third corner C3 at the intersection of the second short side 21c and the second long side 21d, and a fourth corner C4 at the intersection of the second long side 21b and the second short side 21f. For example, the zipper 40 extends from the first corner C1 to the second corner C2. The zipper 40 extends along the diagonal of the outer fabric 21. In this case, the core material 2 can be easily inserted into and removed from the bedding cover 10.

[0031] For example, the bedding cover 10 has an opening 46 into which a hand can be inserted. The length of the opening 46 (for example, the length in the first direction D1) is such that at least a portion of a hand can be inserted into the opening 46. The length of the opening 46 is, for example, 5 cm or more and 30 cm or less (15 cm as an example). The opening 46 is a slit formed between the outer fabric 21 and the lining 22. The opening 46 is the part where the outer edge 21j of the outer fabric 21 is not sewn to the outer edge 22j of the lining 22.

[0032] The bedding cover 10 has, for example, a plurality of openings 46. The openings 46 are formed at the ends of the first long side 22d and the second long side 21d located at the ends in the second direction D2, opposite to the first direction D1, and at the ends of the first long side 22b and the second long side 21b located at the ends opposite to the second direction D2, in the first direction D1.

[0033] For example, the openings 46 are formed at the third corner C3 and the fourth corner C4, respectively. The bedding cover 10 has an opening 46 extending from the third corner C3 in a first direction D1, and an opening 46 extending from the fourth corner C4 in the opposite direction to the first direction D1. The third corner C3 and the fourth corner C4 are, for example, the points on the bedding cover 10 that are furthest from the zipper 40.

[0034] Therefore, by having an opening 46 extending from the third corner C3 and an opening 46 extending from the fourth corner C4, it is possible to reach inside the bedding cover 10 through the opening 46 and pull the core material 2 to the point furthest from the wire fastener 40 (the third corner C3 and the fourth corner C4). Thus, the core material 2 can be easily inserted into the bedding cover 10.

[0035] For example, the outer fabric 21 is identical to the lining fabric 22. In the following, when it is not necessary to distinguish between the outer fabric 21 and the lining fabric 22, the outer fabric 21 and the lining fabric 22 may each be described as fabric 20. Also, the top surface 21g and the bottom surface 22g may each be described as outer surface 20g, and the bottom surface 21h and the top surface 22h may each be described as inner surface 20h.

[0036] Figure 4 is a schematic cross-sectional view of the fabric 20. As shown in Figure 4, for example, the outer surface 20g and the inner surface 20h are napped. Fabric 20 is a fabric that has undergone both a napping process, which will be described later, and a resin processing process, which involves attaching resin 26. Fabric 20 has, for example, fibers 25 obtained by the napping process and resin 26 obtained by the resin processing on the outer surface 20g and the inner surface 20h.

[0037] For example, the amount of wool 25 on the inner surface 20h is greater than the amount of wool 25 on the outer surface 20g. The napping process is, for example, a light napping process. By applying a light napping process, damage to the thin fabric 20 can be prevented more reliably. In a light napping process, for example, a roller-shaped abrasive (sandpaper as an example) is applied to the fabric 20 to make it napped. This napping process is also called sanding. In the case of this light napping process and sanding process, it is possible to avoid damaging the fabric 20 compared to processes such as scraping the fabric with a needle.

[0038] The resin 26 is, for example, a liquid resin before it adheres to the fabric 20, and a granular rubber material when it is attached to the fabric 20. Because the resin 26 is a granular rubber material, the fabric 20 can be made less slippery and have a smooth texture.

[0039] For example, resin 26 is a polyacrylate resin. Resin 26 may be methyl acrylate or ethyl acrylate. Resin 26 may contain methyl acrylate. Resin 26 may also be an acrylic resin agent. In this case, the fabric 20 will have appropriate tackiness, making the fabric 20 even less slippery. Resin 26 may also be an auxiliary agent or finishing agent for the textile industry. In this case, it is possible to increase the flexibility of the fabric 20 and give the fabric 20 a glossy finish.

[0040] Fabric 20 has a brushed finish, which makes it less slippery and enhances grip. Fabric 20 also has a resin coating, which further enhances grip and makes it feel softer and less uncomfortable. Furthermore, the brushed finish on fabric 20 reduces the sticky feeling of the resin.

[0041] For example, both the outer surface 20g and the inner surface 20h of the fabric 20 are treated with a napping process and a resin coating. However, the napping process and resin coating may be applied to only one of the outer surface 20g or the inner surface 20h. For example, the fabric 20 is made of polyester. Alternatively, the fabric 20 may be made of TC material (a blend of polyester and cotton). In this case, for example, the polyester ratio of the fabric 20 is 80%, and the cotton ratio of the fabric 20 is 20%. Furthermore, the fabric 20 may be made of blanket-type fabric. Thus, the material of the fabric 20 is not particularly limited.

[0042] Next, an example of the process for manufacturing a bedding cover according to this embodiment will be described. Below, an example of the manufacturing method for the bedding cover 10 will be described with reference to the flowchart in Figure 5. First, two pieces of fabric 20 that make up the bedding cover 10, namely the outer fabric 21 and the lining fabric 22, are made. A base roll of fabric 30 (see Figure 6) is prepared, which will be the basis for the outer fabric 21 and the lining fabric 22 (the process of preparing the fabric, step S1). The fabric 30 has a first surface 30g that extends in the in-plane direction of the fabric 30 and a second surface 30h that is opposite to the first surface 30g.

[0043] Fabric 30 is made of, for example, polyester material. For example, tension is applied to fabric 30 and it is washed, then the tension is released and fabric 30 is dried. After that, the following napping process is performed. Alternatively, fabric 30 may be made of TC material. In this case, for example, the fluff of fabric 30 is removed and the fabric 30 is descaled, impurities are removed from fabric 30 and fabric 30 is bleached. After that, the napping process is performed.

[0044] In the napping process, both the first side 30g and the second side 30h of the fabric 30 are napping (napping process, step S2). Alternatively, napping may be applied to only one of the first side 30g or the second side 30h, or at least one of the first side 30g or the second side 30h may be napping.

[0045] For example, a light napping process is applied to at least one of the first surface 30g and the second surface 30h. Alternatively, both the first surface 30g and the second surface 30h may be subjected to the light napping process. In the light napping process, the fabric 30 is made fluffy by rolling a roller wrapped with abrasive paper over the fabric 30. The abrasive paper is, for example, sandpaper or emery paper.

[0046] For example, a roller wrapped with abrasive paper is rolled over both the first surface 30g and the second surface 30h to apply a light napping finish to both surfaces. For example, the first surface 30g of the fabric 30 is subjected to a light napping finish at least once, while the second surface 30h of the fabric 30 is subjected to a light napping finish multiple times.

[0047] On the first side 30g, a roller wrapped in abrasive paper is applied and rolled once. On the second side 30h, a roller wrapped in abrasive paper is applied and rolled multiple times. In this way, a light napping process is performed on the fabric 30 by applying a roller wrapped in abrasive paper and rolling the roller.

[0048] The number of times the fine napping process is applied to the second side 30h is greater than the number of times the fine napping process is applied to the first side 30g. For example, the first side 30g is napped once, while the second side 30h is napped two or more times and five or less times (five times as an example). In this case, the first side 30g can be made to feel good against the skin, and the coefficient of friction of the second side 30h can be increased compared to the first side 30g, thereby more reliably suppressing slippage on the second side 30h. In addition, by limiting the number of times the fine napping process is applied to the second side 30h to five or less, damage to the second side 30h can be more reliably suppressed, even if the fabric 30 is a thin fabric.

[0049] As described above, after the napping process is completed on the fabric 30, the fabric 30 is dyed (fabric dyeing process). Then, if the fabric 30 is made of TC material, the fabric 30 is washed and dried. In the case of TC material, the fabric 30 is washed and dried because it is pigment dyed.

[0050] The fabric 30 is subjected to resin processing (resin processing step, step S3). At this time, the resin 26 is applied to the napped surface of the fabric 30. As shown in Figure 6, in the resin processing, the fabric 30 is transported and placed into a recess 3 containing the resin 26, so that the resin 26 is applied to the napped surface of the fabric 30. For example, the recess 3 may be a water tank. As an example, the volume of the recess 3 is 200 kL (kiloliters).

[0051] In resin processing, the resin 26 may be applied to the fabric 30 by immersion dyeing. In this case, the resin 26 is applied to the fabric 30 by immersing it in the liquid resin 26 stored in the recess 3. In resin processing, the resin 26 may also be applied to the fabric 30 by dipping. In this case as with immersion dyeing, the fabric 30 is immersed in the liquid resin 26 stored in the recess 3.

[0052] For example, the first surface 30g and the second surface 30h are resin-treated by immersing the fabric 30 in liquid resin 26. The time the fabric 30 is immersed in the liquid resin 26 is, for example, 1 second or more and 10 seconds or less. However, the time the fabric 30 is immersed in the liquid resin 26 is not particularly limited. For example, the fabric 30 moves inside the recess 3 while immersed in the resin 26, and is transported out of the recess 3 after a predetermined time has elapsed since immersion in the resin 26. As an example, the movement speed of the fabric 30 is 60 m / min. The predetermined time is, for example, 1 second or more and 10 seconds or less.

[0053] The resin-coated fabric 30 is transported to a tenter. In the tenter, the fabric 30 is stretched and heated, thereby drying the fabric 30 (fabric drying process). After that, the fabric 30 is cut to obtain two pieces of fabric 20 (front fabric 21 and back fabric 22). The second surface 30h of fabric 30 becomes the inner surface 20h of fabric 20, and the first surface 30g of fabric 30 becomes the outer surface 20g of fabric 20.

[0054] After obtaining the two pieces of fabric 20, the zipper 40 is sewn onto the outer fabric 21 as shown in Figure 2 (step S4, the process of sewing on the zipper). At this time, the zipper 40 is sewn onto the outer fabric 21 so that it extends diagonally with respect to the first direction D1 and the second direction D2.

[0055] Next, the outer fabric 21 is placed on top of the lining 22 so that they are aligned in the third direction D3. As shown in Figures 2 and 3, the lower surface 21h of the outer fabric 21 is placed on top of the upper surface 22h of the lining 22 in the third direction D3 (overlapping process). At this time, the outer fabric 21 is positioned on top of the lining 22 such that the second long side 21b is on top of the first long side 22b, the second short side 21c is on top of the first short side 22c, the second long side 21d is on top of the first long side 22d, and the second short side 21f is on top of the first short side 22f.

[0056] Then, the outer edges 22j of the lining 22 and the outer edges 21j of the outer fabric 21 are sewn together (step S5). The bedding cover 10 is manufactured by sewing together the outer edges of the outer fabric 21 and the lining 22 which are overlapped in the third direction D3 (for example, a part of the outer edge 21j and a part of the outer edge 22j) (process of manufacturing the bedding cover). At this time, an opening 46 is formed in the outer edge 22j of the lining 22, which is the part where the outer edge 21j of the outer fabric 21 is not sewn together. For example, two of the aforementioned openings 46 are formed. The bedding cover 10 is completed after the above process.

[0057] The effects and advantages obtained from the bedding cover 10 and the manufacturing method of the bedding cover 10 according to this embodiment will be described. The bedding cover 10 and the manufacturing method of the bedding cover 10 are manufactured having a lining 22 extending in a first direction D1 and a second direction D2, and an outer fabric 21 that is overlapped with the lining 22 in a third direction D3. The upper surface 22h of the lining 22 and the lower surface 21h of the outer fabric 21 are each subjected to a napping process. By applying the napping process, the upper surface 22h of the lining 22 and the lower surface 21h of the outer fabric 21 can be made fluffy.

[0058] The upper surface 22h of the lining 22 and the lower surface 21h of the outer fabric 21 are treated with a resin coating, which involves applying resin 26 to each surface. By applying resin 26 to the fuzzy upper surface 22h of the lining 22 and the lower surface 21h of the outer fabric 21, the fabric 20 becomes less slippery and has a better feel against the skin.

[0059] In the bedding cover 10, the upper surface 22h of the lining 22 and the lower surface 21h of the outer fabric 21 can be made to be fluffy to prevent slipping, thereby preventing the core material 2 from shifting when it is placed inside the bedding cover 10, that is, between the upper surface 22h of the lining 22 and the lower surface 21h of the outer fabric 21.

[0060] Therefore, since there is no need to provide a string-like member (such as the aforementioned tee) inside the bedding cover 10 to secure the core material 2, the work of securing the core material 2 to the string-like member and the work of removing the core material 2 from the string-like member are eliminated, making it easy to insert and remove the core material 2. Furthermore, a zipper 40 is sewn onto the outer fabric 21 of the bedding cover 10, which is oriented vertically upward. Therefore, by opening and closing the zipper 40 sewn onto the outer fabric 21, it is possible to further easily insert and remove the core material 2 from the bedding cover 10.

[0061] The lining 22 may be rectangular in shape with first long sides 22b, 22d and first short sides 22c, 22f, and the outer fabric 21 may be rectangular in shape with second long sides 21b, 21d and second short sides 21c, 21f. In the step of sewing the zipper 40 to the outer fabric 21, the zipper 40 may be sewn to the outer fabric 21 such that the zipper 40, which has a length equal to or greater than the length of the second long sides 21b, 21d, extends diagonally with respect to the first direction D1 and the second direction D2.

[0062] In this case, the zipper 40 on the outer fabric 21 has a length equal to or greater than the second long sides 21b, 21d of the outer fabric 21, and extends diagonally with respect to the first direction D1 and the second direction D2. Because the zipper 40, which has a length equal to or greater than the second long sides 21b, 21d, extends diagonally with respect to the first direction D1 and the second direction D2, it is possible to easily insert a hand into the inside of the opened zipper 40, thereby making it even easier to insert and remove the core material 2 into the bedding cover 10.

[0063] The first end 40A of the zipper 40 may be located in the second direction D2 relative to the first reference line L1 which passes through the center O of the outer fabric 21 and extends along the first direction D1, and in the first direction D1 relative to the second reference line L2 which passes through the center O and extends along the second direction D2. The second end 40B of the zipper 40, opposite to the first end 40A, may be located in the direction opposite to the second direction D2 relative to the first reference line L1, and in the direction opposite to the first direction D1 relative to the second reference line L2. In the process of sewing the outer edges 21j and 22j together, a plurality of openings 46 may be formed in the outer edge 22j of the lining 22, which are parts where the outer edge 21j of the outer fabric 21 is not sewn together.

[0064] The opening 46 may be formed at the ends of the first long side 22d and the second long side 21d located at the end in the second direction D2, opposite to the first direction D1, and at the ends of the first long side 22b and the second long side 21b located at the end opposite to the second direction D2, in the first direction D1. In this case, the opening 46 of the bedding cover 10 is formed at the end opposite to the first end 40A of the fastener 40 when viewed from the first reference line L1, and at the end opposite to the second end 40B of the fastener 40 when viewed from the first reference line L1. By forming the opening 46 at a position away from the fastener 40 along the second direction D2, it is possible to reach into the bedding cover 10 through the opening 46 and pull the core material 2 into the bedding cover 10. Thus, the core material 2 can be inserted into the bedding cover 10 more easily.

[0065] In the above description, an example was given in which the openings 46 are formed at the ends of the first long side 22d and the second long side 21d in the direction opposite to the first direction D1, and at the ends of the first long side 22b and the second long side 21b in the first direction D1. However, the openings 46 may also be provided only between the second short side 21c and the first short side 22c, and between the second short side 21f and the first short side 22f. Thus, the position and number of openings 46 can be changed as appropriate.

[0066] By the way, one of the most troublesome tasks for people who do housework is washing bedding. To wash bedding, it is necessary to remove the core material from the bedding cover, and many people find this task troublesome. However, the bedding cover 10 according to this embodiment does not have the aforementioned string-like member, and a long, extending wire fastener 40 is provided on the outer fabric 21, so that the core material 2 can be easily removed from the bedding cover 10 in a short amount of time. Therefore, the bedding cover 10 and the core material 2 can be easily washed, thus reducing the burden of housework.

[0067] The ease of inserting and removing the core material 2 was verified for the bedding cover according to the following embodiment and the bedding cover according to Comparative Examples 1 and 2. The specifications of the bedding cover according to the embodiment and Comparative Examples 1 and 2 are shown below. (Examples) The bedding cover in this embodiment is the bedding cover 10 described above. (Comparative Example 1) The bedding cover according to Comparative Example 1 is equipped with a wire fastener located between the first long side 22b and the second long side 21b, instead of the wire fastener 40 described above. Aside from this, it is identical to the bedding cover 10. (Comparative Example 2) The bedding cover according to Comparative Example 2 has a woven fabric instead of the aforementioned fabric 20, and has eight string-like members inside the bedding cover.

[0068] For each of the bedding covers—10 according to the example, 1 according to comparative example 1, and 2 according to comparative example 2—23 subjects each inserted and removed a futon, and the time taken for each was measured. The results are shown in Table 1 below. In Table 1, "Insertion Time" indicates the average time taken to insert the core material 2 into the bedding cover 10 and close the zipper 40. In Table 1, "Removal Time" indicates the average time taken to open the zipper 40 and remove the core material 2 contained inside the bedding cover 10 from the bedding cover 10. [Table 1]

[0069] As shown in Table 1, the installation time for the bedding cover of Comparative Example 2 was 4 minutes and 26 seconds, and for the bedding cover of Comparative Example 1 it was 2 minutes and 4 seconds, while for the bedding cover of the embodiment it was only 1 minute and 2 seconds. In the bedding cover of the embodiment, by opening the diagonally extending and long linear zipper 40 and inserting the core material 2, the core material 2 can be quickly inserted all the way to the back of the bedding cover, so it was found that the installation time could be reduced to less than half compared to Comparative Examples 1 and 2.

[0070] Regarding removal time, the bedding cover of Comparative Example 2 took 1 minute and 13 seconds, the bedding cover of Comparative Example 1 took 31.01 seconds, while the bedding cover of the Example took only 10.04 seconds. It was found that the bedding cover of the Example, with its long diagonally extending zipper, makes it easier to remove the core material from the bedding cover, thus reducing the removal time to less than one-third of that of Comparative Examples 1 and 2.

[0071] Next, we will describe modified versions of the bedding cover. Some of the components of the various modified versions of the bedding cover described below are the same as some of the components of the bedding cover 10 described above. In the following, components that are the same as those described above will be denoted by the same reference numerals and their descriptions will be omitted as appropriate. Figure 7 shows modified versions of the bedding covers 10A and 10B.

[0072] As shown in Figure 7(a), the zipper 40 of the bedding cover 10A extends diagonally with respect to the first direction D1 and the second direction D2. The first end 40A of the zipper 40 is located between the second long side 21d and the first reference line L1, and the second end 40B of the zipper 40 is located between the second long side 21b and the first reference line L1.

[0073] As shown in Figure 7(b), the first end 40A of the zipper 40 of the bedding cover 10B is located between the second short side 21f and the second reference line L2, and the second end 40B of the zipper 40 of the bedding cover 10B is located between the second short side 21c and the second reference line L2. With the above bedding covers 10A and 10B, the zipper 40 can be made shorter compared to the zipper 40 of the bedding cover 10 described above, thereby reducing the cost of the zipper 40.

[0074] Figure 8 shows bedding covers 10C and 10D relating to further modifications. As shown in Figure 8(a), the zipper 40 of bedding cover 10C extends in the first direction D1. In the manufacturing method of bedding cover 10C, in the step of sewing the zipper 40 to the outer fabric 21, the zipper 40 is sewn to the outer fabric 21 so that it extends in the first direction D1. The zipper 40 of bedding cover 10C extends along the first reference line L1. The zipper 40 of bedding cover 10C is located in the center of the outer fabric 21 in the second direction D2. The zipper 40 of bedding cover 10C extends from the second short side 21c to the second short side 21f.

[0075] In the process of sewing the zipper 40 to the outer fabric 21 of the bedding cover 10C, the zipper 40 is sewn to the outer fabric 21 so that it extends in the first direction D1. In this case, the zipper 40 is sewn so that it extends along the first long sides 22b, 22d and the second long sides 21b, 21d. Therefore, the length of the zipper 40 sewn to the outer fabric 21 can be secured, making it easier to insert and remove the core material 2 into the bedding cover 10C.

[0076] As shown in Figure 8(b), the zipper 40 may extend in the second direction D2. The zipper 40 may extend along the second reference line L2. The zipper 40 may be located in the center of the outer fabric 21 in the first direction D1. The zipper 40 of the bedding cover 10D extends from the second long side 21b to the second long side 21d. In this case, the length of the zipper 40 can be shortened compared to the zipper 40 of the bedding cover 10C described above, thus reducing the cost of the zipper 40.

[0077] The embodiments and various modifications of the bedding cover and the method for manufacturing the bedding cover described herein have been explained above. However, the present invention is not limited to the embodiments or modifications described above. That is, it will be readily apparent to those skilled in the art that the present invention can be modified and changed in various ways within the scope of the gist described in the claims. In other words, the shape, size, number, material and arrangement of each part of the bedding cover, as well as the content and sequence of steps in the method for manufacturing the bedding cover, can be appropriately changed within the scope of the gist described above.

[0078] For example, in the embodiment described above, an example was described in which the resin 26 is attached to the fabric 30 by immersing the fabric 30 in the liquid resin 26 contained in the recess 3. However, the method of attaching the resin 26 to the fabric 30 is not limited to the above example. For example, the resin 26 may be attached to the fabric 30 by spraying the resin 26 onto the fabric 30.

[0079] In the embodiments described above, an example was described in which both the first surface 30g and the second surface 30h of the fabric 30 are subjected to napping and resin processing. However, it is sufficient for at least one of the first surface 30g and the second surface 30h to be subjected to napping and resin processing, and it is also possible for only one of the first surface 30g and the second surface 30h to be subjected to napping and resin processing.

[0080] In the embodiments described above, an example was given in which a fine napping process was performed on the fabric 30 by rolling a roller wrapped with abrasive paper over the fabric 30 to make it fluffy. However, depending on the type of fabric 30, a normal napping process may be performed on the fabric 30. For example, the fabric 30 may be passed through a needle napping machine equipped with a roller on which multiple needles protrude from the surface, and the fabric 30 may be brought into contact with the surface of the roller of the needle napping machine to perform the napping process.

[0081] In the embodiments described above, an example was given in which the bedding cover 10 is a duvet cover. However, the bedding cover may also be a fitted sheet cover or a cushion cover, and is not limited to a duvet cover. For example, the bedding cover may be a pillowcase. In this case, the surface of the pillow can be made to feel good against the skin, and the shifting of the core material (pillow body) inside the pillowcase can be suppressed.

[0082] In the embodiments described above, an example was described in which the bedding cover 10 has an opening 46. The position and number of this opening 46 can be changed as appropriate. The opening 46 may be provided in at least one of the following locations: between the second long side 21b and the first long side 22b, between the second short side 21c and the first short side 22c, between the second long side 21d and the first long side 22d, and between the second short side 21f and the first short side 22f. The number of openings 46 may be one or three or more. [Explanation of symbols]

[0083] 1…Bedding, 2…Core material, 3…Recess, 10,10A,10B,10C,10D…Bedding cover, 20…Fabric, 20g…Outer surface, 20h…Inner surface, 21…Outer fabric, 21b…Second long side, 21c…Second short side, 21d…Second long side, 21f…Second short side, 21g…Top surface, 21h…Bottom surface, 21j…Outer edge, 22…Lining, 22b…First long side, 22c…First short side, 22d…First long side, 22f…First short side, 22g…Bottom surface, 22h…Top surface, 22j ...outer edge, 23...thread, 25...wool, 26...resin, 30...fabric, 30g...first side, 30h...second side, 40...wire fastener, 40A...first end, 40B...second end, 41...element, 42...slider, 46...opening, B...bed, C...bedding, C1...first corner, C2...second corner, C3...third corner, C4...fourth corner, D1...first direction, D2...second direction, D3...third direction, L1...first reference line, L2...second reference line, O...center.

Claims

1. A lining having a first long side extending in a first direction and a first short side extending in a second direction which intersects the first direction, A method for manufacturing a bedding cover comprising: an outer fabric having a second long side extending in the first direction and a second short side extending in the second direction, and being superimposed on the lining in a third direction which intersects the first and second directions, The process involves applying a napping finish to the upper surface of the lining and the lower surface of the outer fabric, The process of applying resin to the upper surface of the lining fabric that has been subjected to the aforementioned napping process, and to the lower surface of the outer fabric that has been subjected to the aforementioned napping process, thereby applying resin treatment to the lining fabric and the outer fabric, respectively. The process of sewing the zipper onto the aforementioned outer fabric, The process of overlapping the lower surface of the outer fabric with the upper surface of the lining in the third direction, A process of sewing together the outer edge of the lining and the outer edge of the outer fabric, Equipped with, A method for manufacturing bedding covers.

2. The lining is rectangular in shape, having a pair of first long sides and a pair of first short sides. The surface fabric is rectangular in shape, having a pair of second long sides and a pair of second short sides. In the process of sewing the zipper onto the outer fabric, The zipper is sewn to the outer fabric such that the zipper has a length equal to or greater than the length of the second long side and extends diagonally with respect to the first and second directions. A method for manufacturing a bedding cover according to claim 1.

3. The first end of the wire fastener is It is located in the second direction from a first reference line that passes through the center of the surface fabric and extends along the first direction, and in the first direction from a second reference line that passes through the center and extends along the second direction, The second end of the wire fastener, opposite to the first end, It is located in the direction opposite to the second direction from the first reference line, and in the direction opposite to the first direction from the second reference line, In the process of sewing the outer edges together, multiple openings are formed in the outer edge of the lining, which are portions where the outer edge of the outer fabric is not sewn together. The opening is formed at the end of the first long side and the end of the second long side opposite to the first direction, and at the end of the first long side and the end of the second long side opposite to the second direction, A method for manufacturing a bedding cover according to claim 2.

4. The lining is rectangular in shape, having a pair of first long sides and a pair of first short sides. The surface fabric is rectangular in shape, having a pair of second long sides and a pair of second short sides. In the process of sewing the zipper onto the outer fabric, the zipper is sewn onto the outer fabric such that it extends in the first direction. A method for manufacturing a bedding cover according to claim 1.

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