JP7540042B2 - mattress - Google Patents

Description

The present invention relates to a mattress.

Mattresses are difficult to dismantle, and so they are often disposed of in landfills. However, in recent years, there has not been enough landfill space in Japan, and the country is struggling to find a way to dispose of the waste. This has led to a demand for mattresses that are easy to dismantle and suitable for recycling.

For example, Patent Document 1 discloses a dismantling processing device used to separate the exterior body and spring unit of a mattress. Patent Document 2 discloses a mattress structure designed to make it easier to dismantle. Even taking into account Patent Documents 1 and 2, there is still room for improvement in the technology for dismantling mattresses.

Patent No. 3459221 Japanese Patent Application Publication No. 9-191976

One of the objectives of the present invention is to provide a mattress that can improve work efficiency during dismantling.

A mattress according to one aspect of the present invention comprises an inner body, an outer body including a first portion and a second portion that cover the inner body, and an edge tape that connects the first portion and the second portion, and is configured such that the first portion and the second portion can be separated by pulling the edge tape and peeling it off from the outer body.

In one embodiment, the device further includes a tab at least a portion of which is located outside the exterior body. The edge tape has a first end and a second end, and is sewn to the periphery of each of the first and second parts with the first and second ends overlapping. The tab is sewn to at least one of the first and second parts together with the area of the edge tape where the first and second ends overlap, and a portion of the tab overlaps with the area and the second end except for the area, and does not overlap with the first end except for the area. The second end is overlapped on the outside of the first end.

In one embodiment, the edge tape has a first end and a second end, and is sewn to the periphery of each of the first and second parts with the first and second ends overlapping by a pair of parallel seam lines. The tab is sewn to at least one of the first and second parts by one of the pair of seam lines, together with the area of the edge tape where the first and second ends overlap, and does not overlap the other of the pair of seam lines.

In one embodiment, the first portion covers the bottom and side surfaces of the inner body, and the second portion covers the top surface of the inner body. The tab overlaps one of the pair of seam lines that is located on the first portion side, but does not overlap the other of the pair of seam lines that is located on the second portion side.

The present invention provides a mattress that can improve work efficiency during dismantling.

FIG. 1 is a schematic perspective view of a mattress according to one embodiment. FIG. 2 is an enlarged schematic perspective view showing the vicinity of the tab shown in FIG. FIG. 3 is a perspective view that shows a schematic diagram of a stage in the mattress dismantling process. FIG. 4 is a schematic perspective view of an inner body provided in the mattress. FIG. 5 is a schematic cross-sectional view of an inner body in the vicinity of a corner. FIG. 6 is a schematic exploded view of elements of the interior body that are disposed inside the wall member, as viewed from the bottom side. FIG. 7 is a schematic cross-sectional view of a block and a felt sheet included in a spring unit. 8A-8D are schematic cross-sectional views illustrating the steps involved in forming the wall member. FIG. 9 is a schematic plan view showing an example of the arrangement of plates when forming a wall member.

An embodiment will be described with reference to the drawings.
In the following description, the "upper surface" of each element constituting the mattress means the surface facing the side on which a person sits when the mattress is in use, and the "lower surface" of each element means the surface facing the floor when the mattress is in use. Additionally, the "side peripheral surface" and "outer peripheral surface" of each element mean the surface connecting the upper surface and the lower surface.

Figure 1 is a schematic perspective view of a mattress 1 according to this embodiment. As shown in the figure, an X direction, a Y direction, and a Z direction are defined, which are mutually perpendicular. The X direction corresponds to the width direction of the mattress 1. The Y direction corresponds to the length direction of the mattress 1. The Z direction corresponds to the thickness direction of the mattress 1 (the direction from the bottom surface to the top surface of the mattress 1). Viewing the mattress 1 parallel to the Z direction is called a plan view.

The shape of the mattress 1 in a plan view is generally rectangular with short sides along the X direction and long sides along the Y direction. In this case, the four corners of the mattress 1 may be smoothly curved (R-shaped).

The mattress 1 comprises an exterior body 2, an edge tape 3, and a tab 4 (tensile tape). The exterior body 2 has a first portion 21 that covers the bottom and side surfaces of the interior body 5 (see FIG. 4) placed inside it, and a second portion 22 that covers the top surface of the interior body 5. Both the first portion 21 and the second portion 22 are made of a cloth material. The first portion 21 and the second portion 22 may be quilted.

The edge tape 3 connects the first portion 21 and the second portion 22. This closes the exterior body 2 in a bag shape. The edge tape 3 has a generally rectangular shape in a plan view with a short side along the X direction and a long side along the Y direction. The tab 4 is provided approximately in the center of the short side of the edge tape 3.

Figure 2 is a schematic perspective view showing an enlarged view of the vicinity of the tab 4. The edge tape 3 is sewn to the periphery of the first portion 21 and the periphery of the second portion 22 by a pair of parallel stitching lines L.

The edge tape 3 has a first end 31 and a second end 32. The first end 31 is a portion including the end where sewing begins when sewing the edge tape 3 to the first part 21 and the second part 22, and its vicinity. The second end 32 is a portion including the end where sewing ends when sewing the edge tape 3 to the first part 21 and the second part 22, and its vicinity.

The second end 32 is overlapped on the outside of the first end 31. This forms a region R where the first end 31 and the second end 32 overlap. The tab 4 is, for example, loop-shaped, and partially overlaps with the region R. The tab 4 also overlaps with a portion of the second end 32 excluding region R (the right side of region R in the figure), but does not overlap with a portion of the first end 31 excluding region R (the left side of region R in the figure).

In the example shown in FIG. 2, the tab 4 overlaps only one of the pair of suture lines L, and does not overlap the other. The tab 4 is disposed below the second end 32 (on the first portion 21 side), and is preferably located between the first end 31 and the second end 32 in the region R.

The edge tape 3 is sewn to the exterior body 2 from the sewing start end along the sewing direction D1. When this sewing operation reaches the second end 32, the tab 4 is sewn to the exterior body 2 together with the second end 32.

The edge tape 3 and tab 4 configured as described above contribute to smoother removal of the exterior body 2 when dismantling the mattress 1. This effect will be explained using Figures 2 and 3.

Figure 3 is a perspective view that shows a schematic diagram of one scene in the dismantling of the mattress 1. In the dismantling of the mattress 1, the tab 4 is pulled and torn off from the edge tape 3 as shown in the figure. At this time, the lower thread that sews the second end 32 of the edge tape 3 to the exterior body 2 breaks. This makes it easier to peel the second end 32 off the exterior body 2.

Then, the edge tape 3 is pulled in the pulling direction D2 (opposite the sewing direction D1) shown in Figures 2 and 3 to peel it off from the exterior body 2. When it has been peeled all the way to the first end 31, the first part 21 and the second part 22 of the exterior body 2 are completely separated. This allows the interior body 5 arranged inside the exterior body 2 to be removed.

Next, the structure of the inner body 5 will be described with reference to FIGS.
Fig. 4 is a schematic perspective view of the inner body 5. The inner body 5 has an upper surface FA and a lower surface FB. In the example of Fig. 4, the inner body 5 has a substantially rectangular shape in a plan view and has four corners C1, C2, C3, and C4. The corners C1, C2, C3, and C4 may be smoothly curved (R-shaped).

Figure 5 is a schematic cross-sectional view of the interior body 5 near the corner C1. The interior body 5 includes a spring unit 6, protective materials 71A and 71B, cushion materials 72A and 72B, a sheet material 8, and a wall member 9.

Protective material 71A is disposed on the upper surface side of spring unit 6, and protective material 71B is disposed on the lower surface side of spring unit 6. Cushion material 72A is disposed on the upper surface side of protective material 71A, and cushion material 72B is disposed on the lower surface side of protective material 71B. Sheet material 8 is disposed between spring unit 6 and protective material 71A. Protective materials 71A and 71B can be formed of, for example, felt, sisal, or compressed cotton. Cushion materials 72A and 72B can be formed of, for example, a foam such as urethane foam. Sheet material 8 can be formed of, for example, nonwoven fabric.

The spring unit 6 includes a block 60A, a felt sheet 62A, and a cover 63. The block 60A is a continuous spring made of metal wires 61, such as steel wires, woven at high density, and exerts elastic force along the Z direction. However, the block 60A may also be made up of multiple independent coil springs.

In the cross section shown, felt sheet 62A is located between block 60A and protective material 71B. Cover 63 covers the side surface of block 60A, the edge of the upper surface of block 60A near the side surface, and the edge of the lower surface of block 60A near the side surface.

The wall member 9 is frame-shaped as shown in FIG. 4, and covers the side surfaces of the spring unit 6, the protective materials 71A, 71B, and the cushioning materials 72A, 72B as shown in FIG. 5. The wall member 9 has an inner peripheral surface 90 on the spring unit 6 side, and an outer peripheral surface 91 on the opposite side to the inner peripheral surface 90. The inner peripheral surface 90 contacts the side surfaces of the cover 63, the protective materials 71A, 71B, and the cushioning materials 72A, 72B. The wall member 9 can be formed from a foam such as cold foam.

In such a configuration of the interior body 5, the cushion material 72A and the upper surface of the wall member 9 correspond to the upper surface FA of the interior body 5, and the cushion material 72B and the lower surface of the wall member 9 correspond to the lower surface FB of the interior body 5.

In this embodiment, a portion of the sheet material 8 penetrates the wall member 9 and protrudes toward the outer peripheral surface 91. Hereinafter, this protruding portion is referred to as the extension portion 80.

Furthermore, in this embodiment, the wall member 9 has a slit 92. The slit 92 is formed from the outer peripheral surface 91 toward the boundary between the spring unit 6 and the cushion material 72A, more specifically, toward the boundary between the cover 63 and the protective material 71A. In the cross section of FIG. 5, the slit 92 reaches the inner peripheral surface 90. However, the slit 92 may be formed in the range from the outer peripheral surface 91 to just before the inner peripheral surface 90.

As shown in FIG. 5, the slit 92 is preferably formed directly below the sheet material 8. When the slit 92 is formed in this manner, the portion of the sheet material 8 located within the wall member 9 forms part of the inner surface of the slit 92.

As shown in FIG. 4, the slits 92 and the extensions 80 are provided at each of the corners C1, C2, C3, and C4. A gap is provided between adjacent extensions 80. The portions of the wall member 9 located above and below the sheet material 8 are connected in the area between the adjacent extensions 80.

The slits 92 may be provided at one, two, or three of the corners C1, C2, C3, and C4. The slits 92 may also be provided at positions other than the corners C1, C2, C3, and C4.

Figure 6 is a schematic exploded view of the elements of the interior body 5 that are arranged inside the wall member 9, viewed from the bottom surface FB. In addition to the above-mentioned block 60A and felt sheet 62A, the spring unit 6 includes blocks 60B and 60C and felt sheets 62B and 62C. Blocks 60B and 60C have the same configuration as block 60A, and exert an elastic force along the Z direction.

Blocks 60A, 60B, and 60C are all roughly rectangular in shape when viewed from above, and are aligned in the Y direction. Cover 63 bundles blocks 60A, 60B, and 60C together by covering the side surfaces of blocks 60A, 60B, and 60C and the edges of their upper and lower surfaces near the side surfaces.

The sheet material 8 has a planar shape larger than the protective materials 71A, 71B, the cushioning materials 72A, 72B, and the bundled blocks 60A, 60B, and 60C. The sheet material 8 also has recesses 81 on each side. The peripheral portion of the sheet material 8 excluding these recesses 81 forms the extension portion 80 when the wall member 9 is further provided to manufacture the interior body 5 shown in FIG. 4.

Figure 7 is a schematic cross-sectional view of blocks 60A, 60B, and 60C and felt sheets 62A, 62B, and 62C. Felt sheet 62A covers the underside of block 60A. Felt sheet 62B covers the underside of block 60B. Felt sheet 62C covers the underside of block 60C.

A portion of felt sheet 62B passes between blocks 60A and 60B, covering part of the top surface of block 60A. Another portion of felt sheet 62B passes between blocks 60B and 60C, covering part of the top surface of block 60C.

Here, the steps relating to the formation of the wall members 9 in the manufacturing method of the mattress 1 will be described.
8 is a schematic cross-sectional view showing a process for forming the wall member 9. When forming the wall member 9, a laminate M in which cushion material 72B, protective material 71B, sheet material 8, spring unit 6, protective material 71A, and cushion material 72A are stacked in this order is placed on a workbench 100. Furthermore, a plurality of plates PL are arranged between the sheet material 8 and the spring unit 6. The plates PL are made of, for example, plastic.

The workbench 100 is provided with a number of frame bodies 110. The frame bodies 110 are connected to the ends of the workbench 100, for example, by hinges, and can be rotated from a lying position as shown by the dashed lines to an upright position as shown by the solid lines. The frame bodies 110 are provided on the four sides of the laminated body M. When the frame bodies 110 are upright, the side peripheral surfaces of the laminated body M are surrounded by the frame bodies 110.

Figure 9 is a schematic plan view showing an example of the arrangement of the plates PL. The plates PL are arranged at each corner of the laminate M so as to protrude from the laminate M. Each plate PL comes into contact with the upright frame 110 as shown in Figure 8.

With the frame 110 in an upright position, liquid agent Q, which will become the base of the wall member 9, is injected inside the frame 110. The injected liquid agent Q foams, forming the wall member 9. After the wall member 9 is formed, each plate PL is removed. As a result, slits 92 corresponding to the shape of each plate PL are formed in the wall member 9. The mattress 1 is then completed through a process in which the first part 21 and the second part 22 of the exterior body 2 are connected with the edge tape 3, among other steps.

When dismantling the mattress 1, as explained with reference to FIG. 3, the edge tape 3 is peeled off from the exterior body 2, the first part 21 and the second part 22 are separated, and the interior body 5 is removed.

Next, the protective material 71A and the cushioning material 72A are separated from the spring unit 6 and the wall member 9. In this embodiment, the slits 92 and the sheet material 8 make this task easy.

In other words, when the end of the wall member 9 on the upper surface FA side is lifted near the slit 92, the wall member 9 easily tears starting from the slit 92. By also lifting the extension portion 80 that penetrates the wall member 9 and protrudes toward the outer peripheral surface 91, the wall member 9 becomes even more likely to tear in the area where the extension portion 80 is provided. Since the sheet material 8 is located on the lower surface side of the protective material 71A and the cushion material 72A, the protective material 71A and the cushion material 72A are separated from the spring unit 6 together with the sheet material 8.

When the protective material 71A, the cushioning material 72A, and the sheet material 8 are separated, the upper surface side of the spring unit 6 is exposed. In this state, the blocks 60A, 60B, and 60C are each removed. As shown in FIG. 7, the felt sheets 62A, 62B, and 62C mainly cover the lower surface sides of the blocks 60A, 60B, and 60C, but do not cover the upper surface sides. Therefore, the felt sheets 62A, 62B, and 62C are unlikely to get in the way of the work of removing the blocks 60A, 60B, and 60C.

In this way, with the structure of the mattress 1 according to this embodiment, the work of removing the blocks 60A, 60B, and 60C when dismantling the mattress 1 can be carried out extremely efficiently.

The above embodiments do not limit the scope of the present invention to the configurations disclosed in the embodiments. The present invention can be implemented by modifying the configurations disclosed in the present embodiments in various ways.

For example, in the above embodiment, the spring unit 6 includes three blocks 60A, 60B, and 60C, but the number of blocks included in the spring unit 6 is not limited to three, and may be one, two, or four or more.

A mattress can also be constructed by combining the outer body 2 in the above embodiment with an inner body having a structure different from that of the above embodiment. Also, a mattress can also be constructed by combining the inner body 5 in the above embodiment with an outer body having a structure different from that of the above embodiment.

The claims of the original application immediately prior to division are set forth below.
[1]
an inner body including a spring unit, a cushioning material disposed on an upper surface side of the spring unit, and a wall member formed of a foam material surrounding the spring unit and side peripheral surfaces of the cushioning material;
An exterior body covering the inner body,
The inner circumferential surface of the wall member contacts the side circumferential surface of the cushion material,
The wall member has a slit at a corner of the interior body from an outer circumferential surface of the wall member toward a boundary between the spring unit and the cushion material.
mattress.
[2]
an interior body including a spring unit, a cushioning material disposed on an upper surface side of the spring unit, a sheet material disposed between the spring unit and the cushioning material, and a wall member formed of a foam material that surrounds the side peripheral surfaces of the spring unit and the cushioning material;
An exterior body covering the inner body,
The inner circumferential surface of the wall member contacts the side circumferential surface of the cushion material,
At a corner of the inner body, a part of the sheet material penetrates the wall member and protrudes to an outer circumferential surface side of the wall member.
mattress.
[3]
An inner body including a spring unit;
An exterior body including a first portion covering a lower surface of the interior body and a second portion covering an upper surface of the interior body;
an edge tape connecting the first portion and the second portion, the edge tape having a first end and a second end, the first end and the second end being overlapped and sewn to a peripheral edge of each of the first portion and the second portion;
a tab sewn to at least one of the first portion and the second portion together with a region of the edge tape where the first end and the second end overlap;
Equipped with
a portion of the tab is located between the first end and the second end in the region, and another portion of the tab is located outside the exterior body;
mattress.
[4]
A method for manufacturing a mattress according to the above [1] or [2],
placing a laminate including the spring unit and the cushioning material on a workbench;
placing a frame surrounding a side peripheral surface of the laminate placed on the workbench;
forming the wall member of a foam material between the side periphery and the frame;
A manufacturing method comprising:

1...mattress, 2...outer body, 21...first part, 22...second part, 3...edge tape, 4...tab, 5...inner body, 6...spring unit, 60...block, 71A, 71B...protective material, 72A, 72B...cushion material, 8...sheet material, 80...extension, 9...wall member, 92...slit.

Claims (5)

The inner body,
an exterior body including a first portion and a second portion covering the interior body;
an edge tape connecting the first portion and the second portion;
a tab at least a portion of which is located outside the exterior body;
Equipped with
the edge tape is sewn to a peripheral edge of each of the first portion and the second portion;
the tab is sewn to at least one of the first portion and the second portion together with an end of the edge tape;
The thread sewing the end of the edge tape to the exterior body is broken by pulling the tab and tearing it off from the edge tape, and the first part and the second part can be separated by pulling the edge tape and peeling it off from the exterior body.
mattress. the edge tape has a first end and a second end, and is sewn to the peripheral edge of each of the first portion and the second portion with the first end and the second end overlapping each other;
the tab is sewn to at least one of the first portion and the second portion together with a region of the edge tape where the first end and the second end overlap;
a portion of the tab overlaps with the region and a portion of the second end excluding the region, and does not overlap with a portion of the first end excluding the region;
2. The mattress of claim 1. The second end is overlapped on the outside of the first end.
3. The mattress of claim 2. The inner body,
an exterior body including a first portion and a second portion covering the interior body;
an edge tape connecting the first portion and the second portion;
a tab at least a portion of which is located outside the exterior body ;
Equipped with
The first portion and the second portion can be separated by pulling the edge tape and peeling it off from the exterior body,
the edge tape has a first end and a second end, and the first end and the second end are overlapped and sewn to the peripheral edges of the first portion and the second portion by a pair of parallel sewing lines;
the tab is sewn to at least one of the first portion and the second portion by one of the pair of seam lines together with an area of the edge tape where the first end portion and the second end portion overlap, and does not overlap the other of the pair of seam lines;
mattress . The first portion covers a lower surface and a side surface of the interior body,
The second portion covers an upper surface of the inner body,
the tab overlaps one of the pair of suture lines located on the first portion side and does not overlap the other of the pair of suture lines located on the second portion side;
5. The mattress of claim 4.

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