Balanced solid cotton bedding

Abstract

Prevent excessive sinking or deterioration over time of a part of the body and always provide comfortable ease of lying down as bedding. 【Solution means】The balanced solid cotton bedding 10 of the present invention fuses a sheet-shaped second solid cotton material 14, which is softer than the first solid cotton material, onto the first solid cotton material 12 having a hard hardness, and a part of the second solid cotton material 14 is laminated on the first solid cotton material 12. The occurrence of joints between hard solid cotton materials is suppressed, and always provides comfortable ease of lying down.

Description

Technical Field

[0001] The present invention relates to a balanced solid cotton bedding in which synthetic fibers are compressed into a plate shape and a part thereof is made hard, and particularly to a balanced solid cotton bedding using polyester cotton as the synthetic fiber.

Background Art

[0002] As a conventional balanced solid cotton bedding, it has a front part that is formed to be slightly hard to correspond to the head of a person using it as a balanced futon, an intermediate part that is formed hard to correspond to the back and waist, and a soft rear part, and there is a known technique that supports the weight of the body well in balance during use (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above-described known technique, the part hitting the head, the part hitting the back and waist are configured harder than the part hitting the feet, so the body is supposed to be supported well in balance. However, not the entire part from the head to the waist is hard, and a part that functions as a fold considering folding such as triple folding is formed between the part hitting the head and the part hitting the back and waist. Even when the user takes a sleeping position due to this fold, the fold is emphasized, and conversely, a problem of difficulty in sleeping also occurs.

[0005] Therefore, the balanced solid cotton bedding of the present invention aims to always provide a comfortable ease of falling asleep.

Means for Solving the Problems

[0006] In view of the above technical problems, the balanced solid cotton bedding of the present invention is characterized in that a sheet-shaped second solid cotton material that is softer than the first solid cotton material is fused onto the first solid cotton material with a hard hardness, and a part of the second solid cotton material is laminated on the first solid cotton material.

[0007] By arranging the relatively soft second solid cotton material so as to be laminated on the relatively hard first solid cotton material, the occurrence of joints between the hard solid cotton materials is suppressed, and when viewed planarly, the first solid cotton material can obtain a structure surrounded by the soft second solid cotton material. Therefore, according to the balanced solid cotton bedding of the present invention, a comfortable ease of lying down can always be provided.

[0008] According to a preferred embodiment of the present invention, the first and second solid cotton materials are each blended with different types of polyester cotton, and the first solid cotton material and the second solid cotton material can be fused by heat treatment. Further, the second solid cotton material can be folded back while being fed in the feeding direction of the first solid cotton material and laminated on the first solid cotton material.

[0009] According to another preferred embodiment of the present invention, the first solid cotton material is supplied under the second solid cotton material in a web shape, and the first solid cotton material and the second solid cotton material can be fused by heat treatment. Further, the cross section of the first solid cotton material perpendicular to its feeding direction can have curved sides and upper surfaces, and a part of the second solid cotton material can wrap around the end of the bottom of the first solid cotton material so that the first solid cotton material and the second solid cotton material are fused.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

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Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0011] One embodiment of the balanced solid cotton bedding of the present invention will be described with reference to the drawings. This embodiment is an example of a mattress-type balanced solid cotton bedding 10. As shown in FIG. 1, the balanced solid cotton bedding 10 of this embodiment is composed of a first solid cotton material 12 in which non-recycled polyester cotton and recycled polyester cotton are blended, and a second solid cotton material 14 in which non-recycled polyester cotton and recycled polyester cotton are also blended, which are laminated. The first solid cotton material 12 is a solid cotton material with a relatively hard hardness, and is supplied to a heat treatment apparatus in a web-like form together with the second solid cotton material 14, and is fused to the lower central side of the second solid cotton material 14. The second solid cotton material 14 is placed on the first solid cotton material 12 in a method of overlapping while feeding the first solid cotton material 12 in a soft sheet-like form as will be described later, and is fused to the surface of the first solid cotton material 12 by heat treatment.

[0012] For the first solid cotton material 12, in order to make it hard, for example, the blending ratio of low melting point polyester cotton is increased, or thick fibers are used, so that a solid cotton material with a composition that suppresses the so-called sagging over time is used. As the second solid cotton material 14, by mixing recycled polyester cotton and low melting point polyester cotton, a state where polyester cotton that melts temporarily during heat treatment and polyester cotton that does not melt are mixed is created, and from this, by cooling treatment for an extremely short time, the low melting point polyester cotton is instantaneously solidified to obtain a cured polyester material that is hard as a whole and has a high coefficient of restitution. For example, the low melting point polyester cotton has a weight ratio of 10 to 80%, and ordinary polyester cotton including recycled polyester cotton and the like is uniformly mixed at a weight ratio of 20 to 90% to obtain a polyester cotton sheet. A more preferable weight ratio is, for example, 20% to 60% by weight of the low melting point polyester cotton, and a further preferable low melting point polyester cotton can be 25% to 45% by weight. As the low melting point polyester cotton, those in which polyester fibers with an overall low melting point are made into a cotton shape can also be used, and fibers with a different composition such as a core-sheath structure where the core is polyester cotton and the sheath part is copolymerized polyester or polyethylene can also be used. As ordinary polyester cotton, those with a thickness of, for example, 12 to 18 denier are used, and as low melting point polyester cotton, fibers with a thickness of, for example, 4 to 6 denier can be used.

[0013] The second nonwoven material 14 is placed on the first nonwoven material 12 in a manner of overlapping while feeding the first nonwoven material 12 in a particularly soft sheet form. At this stage before the heat treatment, the low-melting polyester fiber also maintains a soft state. When it is overlapped on the first nonwoven material 12, as shown in FIG. 2, it is laminated while reflecting the shape of the first nonwoven material 12. The cross-sectional shape of the first nonwoven material 12 is configured to protrude from the bottom surface to the side portion. When the second nonwoven material 14 is overlapped while feeding the first nonwoven material 12 on the conveyor, there is also a slight gap 16 on the side surface portion of the first nonwoven material 12. However, in the next step, when pressure is applied from the surface for heat treatment, as shown in FIG. 3, the soft second nonwoven material 14 that covered the first nonwoven material 12 wraps around along the surface of the first nonwoven material 12 and hardens while filling the gap 16. As a result, the surface area in close contact with the first nonwoven material 12 increases, and the second nonwoven material 14 hardens in a form that holds the first nonwoven material 12, so the adhesion between the second nonwoven material 14 and the first nonwoven material 12 becomes strong.

[0014] In this embodiment, the mattress-type balanced nonwoven bedding 10 can have a structure made of a plate-shaped cured polyester sheet having a thickness (H) of, for example, 2 cm to 12 cm, more preferably 2.5 cm to 6 cm. The plate size (width W and length L shown in FIG. 1) can be, for example, an outer dimension of 140 cm × 205 cm or slightly smaller, and can also have other sizes, such as outer dimensions of 160 cm × 205 cm, 180 cm × 205 cm, 200 cm × 205 cm, 240 cm × 205 cm, 280 cm × 205 cm, 300 cm × 205 cm. It can also be composed of a single nonwoven sheet, or a structure in which a plurality of nonwoven sheets are overlapped. Regarding the first nonwoven material 12 to be supplied, the height (H) is about 1 cm to 4 cm, and the width (P) is about 1 / 2 to 1 / 4 of the plate size. The first nonwoven material 12 is supplied, for example, in a web shape having a rounded cross-section with a continuous curve. As a result, a gap 16 like an eaves may be generated on the bottom surface. However, since the soft second nonwoven material 14 wraps around along the surface of the first nonwoven material 12 and hardens while filling the gap 16, the gap 16 does not remain in the product.

[0015] In such a balanced solid cotton bedding, since the relatively hard first solid cotton material 12 is disposed in the middle part in the longitudinal direction, excessive sinking of the portion that abuts against the waist and spine when taking a sleeping posture is suppressed, and thus a comfortable ease of falling asleep can always be provided. In addition, since the relatively hard first solid cotton material 12 can also suppress a decrease in resilience due to deterioration over time, the balanced solid cotton bedding of the present embodiment is suitable for long-term use.

[0016] FIGS. 4 and 5 are diagrams showing an apparatus for manufacturing the balanced solid cotton bedding of the present embodiment, and a manufacturing method of the balanced solid cotton bedding using these manufacturing apparatuses will also be described. FIG. 4 is a schematic side view showing the front stage of the apparatus for manufacturing the balanced solid cotton bedding according to the present embodiment, and FIG. 5 is a schematic top view showing the rear stage of the apparatus for manufacturing the balanced solid cotton bedding of the present embodiment. The feeding direction of the sheet-shaped second solid cotton material 14 is from left to right in the drawing at the front stage of the apparatus shown in FIG. 4, but is from top to bottom in the drawing at the rear stage of the apparatus shown in FIG. 5. By the pendulum type feeder 28, the feeding direction of the sheet-shaped second solid cotton material 14 changes at a right angle on the plane.

[0017] First, prepare the first solid cotton material 12 supplied in a web shape and the second solid cotton material 14 supplied in a sheet form. In order to make the shape of the second solid cotton material 14 sheet-shaped, recycled polyester cotton and low-melting-point polyester cotton are put into the blender 20, stirred in the blender 20 to homogenize the raw materials, and the second solid cotton material 14 is taken out from the blender 20 by the roller 22 so as to have a sheet shape. From the roller 22, the second solid cotton material 14 in a sheet shape is conveyed after being separated into an upper sheet and a lower sheet via the guide rollers 24 and 26.

[0018] The second batting material 14 is supplied to the upper end of the pendulum feeder 28 and is stacked so as to reciprocate according to the pendulum motion of the pendulum feeder 28. At this time, the direction of the reciprocating motion of the pendulum feeder 28 is the X direction perpendicular to the conveying direction Y of the balanced batting bedding. While reciprocating in the X direction, that is, changing the supply position in the +X direction and the -X direction, and at the same time sending the whole in the conveying direction Y, the sheet-like second batting material 14 is stacked. From in front of the position where this sheet-like second batting material 14 is stacked, the web-like first batting material 12 is supplied, and the first batting material 12 is arranged so as to slip under the sheet-like second batting material 14 and is conveyed in the Y direction together with the second batting material 14 according to the operation of a conveyor (not shown).

[0019] The second batting material 14 stacked together with the first batting material 12 is pressurized and heated by the heat treatment device 30, and hardening by heat treatment and fusion between the first batting material 12 and the second batting material 14 are performed. Specifically, pressure is applied by a heat roller or the like to press the fibers into a plate shape, and at that time, the low-melting-point polyester is melted and maintained at a temperature that reaches every corner in the sheet. Due to this heating, while the components of the low-melting-point polyester in the sheet are melted by thermocompression bonding, the first batting material 12 and the second batting material 14, which are polyester batting sheets, are conveyed in the heat treatment device 30, and cooling air is blown by a blower located at the end of the heat treatment device 30 to cure the melted low-melting-point polyester component. The compressed polyester batting sheet becomes hard and is cured, reducing the volume of the sheet material and being cured. The cured polyester sheet, especially by mixing low-melting-point polyester batting, creates a state where the polyester batting that temporarily melts during heat treatment and the polyester batting that does not melt are mixed, and from this, by a cooling process for an extremely short time, the low-melting-point polyester batting is instantaneously solidified to obtain a cured polyester sheet that is hard as a whole and has a high coefficient of restitution.

[0020] The solid cotton material 34 that has passed through the heat treatment device 30 has its both ends 14e cut off and separated to have a constant width, and is also separated by the cutting line 32 so as to have one product size. Through these cutting operations, the solid cotton material 34 has a required thickness, has a hard first solid cotton material 12 near the center, and has a second solid cotton material 14 around it.

[0021] In the balanced solid cotton bedding as described above, since the relatively hard first solid cotton material 12 is disposed in the middle part in the longitudinal direction, excessive sinking of the part that abuts against the waist and spine when taking a sleeping posture is suppressed, and thus a comfortable ease of falling asleep can always be provided. In addition, since the relatively hard first solid cotton material 12 can also suppress the decrease in elasticity due to deterioration over time, the balanced solid cotton bedding of the present embodiment is also suitable for long-term use.

Explanation of reference numerals

[0022] 10 Balanced solid cotton bedding 12 First solid cotton material 14 Second solid cotton material 14e Both ends 20 Blender 22 Roller 24, 26 Guide roller 28 Pendulum feeder 30 Heat treatment device 32 Cutting line 34 Solid cotton material

Claims

1. A balance cotton bedding, characterized in that a sheet-shaped second cotton material softer than the first cotton material is fused onto a first cotton material with a hard hardness, and a part of the second cotton material is laminated on the first cotton material.

2. The cotton bedding according to Claim 1, wherein the first and second cotton materials are each blended with different types of polyester cotton, and the first cotton material and the second cotton material are fused by heat treatment.

3. The cotton bedding according to Claim 1, wherein the second cotton material is folded back while being fed in the feeding direction of the first cotton material and laminated on the first cotton material.

4. The cotton bedding according to Claim 1, wherein the first cotton material is supplied as a web under the second cotton material, and the first cotton material and the second cotton material are fused by heat treatment.

5. The cotton bedding according to Claim 1, wherein a cross-section perpendicular to the feeding direction of the first cotton material has curved sides and an upper surface, and a part of the second cotton material wraps around an end of the bottom of the first cotton material, and the first cotton material and the second cotton material are fused.

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