Pocket coil

Abstract

To provide a pocket coil having a cutting line which makes it difficult for breakage caused unexpectedly during the manufacture or use of a mattress to spread. [Solution] The pocket coil 100 of the present invention comprises a bag body 10 in which a number of coil spring accommodating chambers 2 are arranged in a row, and a number of coil springs 3 accommodated one by one in the coil spring accommodating chambers 2. The bag body 10 has a longitudinal fusion line 5 formed in the longitudinal direction of the pocket coil 100 by fusing both ends 11a, 11b in the width direction of a strip-shaped nonwoven fabric 1, a partition fusion line 6 that partitions adjacent coil spring accommodating chambers 2, 2, an upper wall 12 and a lower wall 13 that cover both ends in the axial direction of the coil spring 3, and a side wall 14 that covers the sides of the coil spring 2, and the coil spring 3 is accommodated in the coil spring accommodating chamber 2 with the axial direction being the same as that of the partition fusion line 6. The bag body 10 has a cutting line 4 that is a wavy broken line extending in the longitudinal direction.

Description

[Technical field]

[0001] The present invention relates to a so-called pocket coil that is fitted inside a mattress, and in particular to a pocket coil that has a nonwoven fabric bag body in which a coil spring is fitted and has a cutting line for disassembly. [Background technology]

[0002] In the past, in order to recycle the nonwoven fabric and coil springs of pocket coils 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 provided on the upper and lower walls of a pouch 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 pouch body to prevent the force caused by the expansion and contraction of the coil spring when the mattress is in use from being applied to the perforations.

[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 such that the top and bottom walls of the pouch are attached to the outer cover of the mattress, so that when the outer cover is removed, the pouch of the pocket coil is torn at the same time.

[0005] However, in the pocket coil of Patent Document 2, the coil springs are housed one by one in a bag body formed into a cylindrical shape, so if breakage does not occur at the perforations of some of the bags, there is a risk that all of the perforations cannot be broken 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, making it possible to break the perforations continuously. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] JP 2005-65726 A [Patent Document 2] JP 2012-95785 A [Patent Document 3] JP 2022-180052 A Summary of the Invention [Problem to be solved by the invention]

[0008] However, because the perforations in the pocket coil of Patent Document 3 are continuous and linear, if an external force is applied during the manufacture or use of the mattress and the perforations of the pocket coil are accidentally broken, the breakage will spread along the perforation. The present invention has been made in view of the above problem, and aims to provide a pocket coil with a cutting line that will prevent the spread of breaks that occur unexpectedly 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 installed in a mattress, comprising a bag body in which a number of coil spring accommodating chambers are arranged in a row, and a number of coil springs accommodated one by one in the coil spring accommodating chambers, the bag body being formed from a strip-shaped nonwoven fabric, and comprising a longitudinal fusion line formed in the longitudinal direction of the pocket coil by fusion-bonding both ends in the width direction of the nonwoven fabric, a partition fusion line that is perpendicular to the longitudinal fusion line and partitions adjacent coil spring accommodating chambers, an upper wall and a lower wall covering both ends in the axial direction of the coil spring, and a partition wall covering the sides of the coil spring. A pair The coil spring has a side wall, the coil spring is accommodated in the coil spring accommodating chamber in the same axial direction as the partition fusion line, and the bag body has a cutting line consisting of a wavy dashed line extending in the longitudinal direction.

[0010] Because the pocket coil of the present invention has wavy cutting lines as described above, any breaks that occur along the cutting lines when the mattress is in use can be prevented from progressing along the cutting lines.

[0011] The cutting line is The pair of side walls In this way, when dismantling the mattress, the bag can be easily opened and the coil spring can be removed simply by pulling the upper wall of the bag upward.

[0012] The bag The pair of The cutting lines on the side walls are: Regarding the opposing direction of the pair of side walls It is preferable that the cut lines are provided asymmetrically. This makes it possible to prevent the cut lines on both side walls of the bag from breaking simultaneously when the mattress is in use, etc.

[0013] It is preferable that the cutting line has a discontinuous portion having a larger gap than the gap between the multiple short lines that make up the dashed line, so that the discontinuous portion can prevent the breakage that occurs unexpectedly in the cutting line from progressing.

[0014] The above A pair The cut lines of the side walls both have discontinuities, A pair It is preferable that the cut line of the side wall has a discontinuous portion at a different position in the longitudinal direction. A pair The bag can be torn along the cut lines by pulling the outer cover attached to the upper wall of the bag, and the breaks in both cut lines can be prevented from reaching the discontinuous portion at the same time.

[0015] The discontinuous portion is preferably provided at the top of the crest or the bottom of the valley of the wave 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, by providing a discontinuous portion at the top of the crest or the bottom of the valley of the wavy cutting line that is closest to the covering member and receives the most force when the mattress is in use, it is possible to 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. In this way, when the cutting line straddles the upper wall, the side wall, and the lower wall, it is possible to suppress the spread of an unexpected breakage occurring in the cutting line.

[0017] It is preferable that the partition fusion line has a non-fused portion and the cutting line passes through the non-fused portion, which can prevent 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 wave-shaped, triangular wave-shaped, or rectangular wave-shaped. Effect 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 manufacture or use. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a perspective view showing a pocket coil according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a partially transparent side view of the pocket coil of FIG. 1. [Diagram 3] FIG. 2 is a front view of the pocket coil of FIG. [Figure 4] FIG. 5 is a perspective view showing a pocket coil according to a second embodiment of the present invention. [Diagram 5] FIG. 5 is a partially transparent side view of the pocket coil of FIG. 4. [Figure 6] FIG. 11 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 in the first embodiment. [Figure 9] 1A is a schematic front view showing another example of a longitudinal fusion line provided in a side wall of a pocket coil of the present invention, and FIG. 1B is an enlarged view of part A in (a). [Figure 10] 1A is a schematic front view showing another example of a longitudinal fusion line provided in a side wall of a pocket coil of the present invention, and FIG. 1B is an enlarged view of part B in (a). [Figure 11] 1A is a partial schematic front view, FIG. 1B is a partial schematic side view, and FIG. 1C is a plan view showing another example of a longitudinal fusion line provided in the upper wall of a pocket coil of the present invention. [Figure 12] 1A is a partial schematic front view, FIG. 1B is a partial schematic side view, and FIG. 1C is a plan view showing another example of a longitudinal fusion line provided in the upper wall of a pocket coil of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Hereinafter, an embodiment 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 embodiment.

[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 a coil spring, and a number of coil springs 3, 3, 3..., and is installed as a 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 10 is formed from a strip-shaped nonwoven fabric 1, and has two dashed longitudinal fusion lines 5, 5 in which both widthwise ends 11a, 11b of the nonwoven fabric 1 are overlapped and fused, a number of dashed partition fusion lines 6, 6, ... intersecting at right angles to the longitudinal fusion lines 5, 5, and a number of coil spring accommodating chambers 2, 2, ... partitioned by the partition fusion lines 6, 6, ... (see FIG. 2). The nonwoven fabric 1 used for the bag 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, 2, . . . accommodates one coil spring 3 in the same axial direction as the partition fusion lines 6, 6, . The bag body 10 has an upper wall 12 and a lower wall 13 which cover both axial ends of the coil spring 3, and side walls 14, 14 which 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 be used.

[0025] 2, the bag body 10 is formed by folding the widthwise ends 11a, 11b of the strip-shaped nonwoven fabric 1 so as to overlap each other on one of the side walls 14 and ultrasonically fusing them 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 or three or more, and may be a continuous solid line. Furthermore, as shown in Fig. 9, the longitudinal fusion lines 5 may be provided by turning the widthwise ends 11a, 11b of the nonwoven fabric 1 inside out. As shown in Fig. 10, the widthwise ends 11a, 11b of the nonwoven fabric 1 may be aligned, and the longitudinal fusion lines 5 may be provided at position 11d of the base of the band-shaped connection margins 11c, 11c, and the connection margins 11c, 11c may 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 the widthwise ends 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 strip 11c vertically installed on the upper surface 12 of the bag body 10. Furthermore, as in the example of Fig. 12, both widthwise ends 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 fusion parts 6a, 6a, ... are arranged at intervals, but it may be arranged in 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, and stacking and fusing a total of four nonwoven fabrics. The partition fusion line 6 also has a non-fused part 61 where there is no fused part 6a in the vertical direction.

[0029] 1 and 2, the cutting lines 4 are sinusoidal (curved wave-like) and dashed. Two cutting lines 4 are provided, one on each of the left and right side walls 14, 14 (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 (the left and right direction in FIG. 2).

[0030] In the example of Figure 2, the cutting line 4 is provided above the longitudinal fusion lines 5,5 on the side wall 14, but it may also be provided below the longitudinal fusion lines 5,5, or two cutting lines may be provided, one above and one below the longitudinal fusion lines 5,5, or three or more cutting lines may 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 makes it possible to prevent insects such as bedbugs and mites, and dust such as house ducts, allergens, and mold from entering the inside of 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 thereto and may be formed in other curved wave shapes, triangular wave shapes, rectangular wave shapes, etc. 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 FIG. 8, the cutting line 4 has a discontinuous portion 4a at the crest 4b, which is wider than the interval d of the broken lines of the cutting line 4. In this way, by providing the discontinuous portion 4a at the crest 4b of the cutting line 4, which is 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 breaking unexpectedly during use of the mattress. When the cutting line 4 is provided closer to the lower wall 13 than the upper wall 12, it is preferable to provide the discontinuous portion 4a at the bottom 4c of the valley of the cutting line 4 that is closest to the lower wall 13. However, the discontinuous portion 4a may be provided at a location other than the crest 4b or the bottom 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 cutting line 4 and the fused portion of the partition fusion line 6 intersect, the intersecting portion becomes hard, making it difficult to cut along the cutting line 4. In this way, by having the cutting line 4 pass through the non-fused portion 61 of the partition fusion line 6, the bag body 10 can be smoothly cut and disassembled along the cutting line 4.

[0035] It is preferable that the non-fused portion 61 is greater 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 of the coil spring accommodating chambers 2 differs from the wave pitch of the cutting line 4.

[0036] When disassembling the pocket coil 100, the covering such as urethane foam joined to the top wall 12 of the pocket coil 100 is lifted up so as to be peeled off from the pocket coil 100. Then, the top wall 12 of the pocket coil 100 is pulled by the urethane foam, etc., and the bag body 10 is cut and released along the cutting lines 4, 4 on both side walls 14, 14 of the pocket coil 100. After that, the coil spring 3 is taken out from the inside, and the coil spring 3 and the bag body 10 (nonwoven fabric 1) are separated. In this manner, since the cutting 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 upper wall 12 upward.

[0037] (Action and effect) 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 shape, a breakage that occurs along the cutting line 4 during use of the mattress 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 by simply pulling the upper wall 12 of the bag body 10 upward. (3) The cut lines 4, 4 of the side walls 14, 14 of the bag body 10 are arranged asymmetrically on either side of the bag body 10, so that the cut lines 4, 4 of the side walls 14, 14 can be prevented from breaking simultaneously when the mattress is in use, etc. (4) Since the discontinuous portion 4a is provided in the cutting line 4, the discontinuous portion 4a can suppress the propagation of the fractured portion generated in the cutting line 4. (5) When tearing the upper 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 impeded. In the first embodiment, since 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, it is possible to prevent the breaking points of the cutting lines 4, 4 from reaching the discontinuous parts 4a, 4a at the same time, and therefore it is easy to cut the cutting lines 4, 4 when dismantling the bag body 10. (6) Since the discontinuous portion 4a is provided at the crest 4b of the wave crest or the bottom 4c of the valley in the cutting line 4, it is possible to effectively prevent the cutting line 4 from suddenly breaking when the mattress is in use. (7) Since the cutting lines 4, 4 pass through the non-fused portions 61 of the partition fusion lines 6, the cutting lines 4, 4 do not harden at the intersections with the partition fusion lines 6, which makes it difficult to cut the lines 4, 4.

[0038] Second embodiment 4 and 5 show a pocket coil 200 according to the 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, and 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. In addition, in the pocket coil 200, two parallel wavy and broken cutting lines 204, 204 are provided so as to extend in the longitudinal direction of the upper wall 12 of the bag body 10. The cutting lines 204 are made of melting lines by ultrasonic waves 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, so that all of the coil spring accommodating chambers 2 can be disassembled consecutively by pulling the portion between the two cutting lines 204, 204. 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 with reference to Figures 6 and 7. The pocket coil 300 has the partition fusion line 206 similar to that of 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 the 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 affixed to the covering. When dismantling the pocket coil 300, all of the coil spring accommodating chambers 2 can be disassembled consecutively by pulling the portion between the two cutting lines 304, 304. Also 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-mentioned 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. The cutting line may be provided on either the upper wall, the lower wall, or the side wall of the bag body, or may be provided on some or all of them. Any number of cutting lines may be provided on one of the upper wall, the lower wall, and the side wall. The cutting lines on both side walls may be provided symmetrically with respect to the bag body, and the positions of the discontinuous parts may be the same in the longitudinal direction of the bag body. The cutting line may not have a discontinuous part, or the discontinuous part may be provided at a location other than the crest of the wave of the cutting line or the bottom of the valley. The partition fusion line may not have a non-fused part, and the cutting line may cross the fused part 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 sine wave or curved wavy line, but may also be a triangular wave or rectangular wave. The cutting line is not limited to a fusion line, but may be a perforation consisting of multiple slits penetrating the nonwoven fabric. [Explanation of symbols]

[0043] 100,200,300 Pocket coil 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 spring 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 are accommodated in the coil spring accommodation chambers one by one; Equipped with The bag body is formed of a strip-shaped nonwoven fabric, and both ends in the width direction of the nonwoven fabric are fused to each other. A longitudinal fusion line formed in the longitudinal direction of the pocket coil and a fusion line perpendicular to the longitudinal fusion line A partition fusion line that partitions adjacent coil spring accommodating chambers and both ends of the coil spring in the axial direction and a pair of side walls that cover the sides of the coil spring. The coil spring is accommodated in the coil spring accommodation chamber in the same axial direction as the partition fusion line. It is accepted, The bag body has a cutting line formed of a wavy broken line extending in the longitudinal direction. Pocket coil.

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

3. The pocket coil according to claim 2 , wherein the cutting lines provided on the pair of side walls of the bag body are provided asymmetrically in a direction in which the pair of side walls face each other.

4. The cutting line has discontinuous portions with intervals wider than the intervals between the multiple short lines that make up the dashed line. The pocket coil according to claim 1 or claim 2.

5. The cutting lines of the pair of side walls each have a discontinuous portion, The pocket coil according to claim 2 , wherein the cut lines of the pair of side walls have discontinuous portions at different positions in the longitudinal direction.

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

7. The cutting line is provided so as to extend across the side wall and the upper wall, or the side wall and the lower wall of the bag body. The pocket coil according to claim 1 or claim 2.

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

9. The cutting line according to claim 1 or 2, wherein the cutting line is curved, triangular, or rectangular. Pocket coil included.

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