JPH10234547A - Manufacture of feather quilt - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a feather quilt extremely easily with low man-hour, by forming a frame body part of lattice gore cloth to be the quilt inner part by sewing, etc., overlapping desired surface and backside cloth above and under a flattened frame body part and assembling the whole by mechanizable heat adhesion. SOLUTION: Main gore cloth 4A and orthogonally crossing fore cloth 4C with prescribed width almost same as that of the main gore cloth 4A and slightly longer than a prescribed lattice interval length are arranged by longitudinal directions of both and overlapped and one end of the orthogonally crossed gore cloth is joined by sewing in the width direction. After that, each of upper and lower end parts of two main gore cloth overlapped by trueing up directions of opposite faces of sectioned faces is trued up a band body 6 including a thermosetting adhesive layer putting the adhesive layer outside and overlapped and joined by sewing, etc., in a line along almost the center of the band body 6.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a duvet, and more particularly, to a duvet having a structure similar to a known structure which can be easily filled with feathers in each of the small compartments.
And a method of manufacturing a duvet which employs a manufacturing process for easily and inexpensively manufacturing the same with a small amount of work.

[0002]

2. Description of the Related Art In general, a duvet is filled with a feather as a filler between the front and back fabrics (side fabric). In particular, in a duvet, in order to prevent uneven distribution of feathers, a small compartment is formed between the front and back side lands, and the interior is generally filled with feathers. To fill feathers, for example, there is a method in which when a gore cloth is sewn on the front and back linings to form a small section, feathers are put into the small section by a desired amount and the small section is sealed and sewn. However, this method requires a lot of work, so when the small section is made of gore cloth, the passage of the pipe for feeding feathers is formed in the small section gore cloth, and when the outer material and the lining are sewn at the periphery of the futon, one step is required. A method is often adopted in which the feather feeding pipe is inserted into the small section through the pipe passage and the feather is fed into the small section from the opening.

[0003] In order to facilitate the filling operation using such a filling pipe and to prevent the movement of feathers between the small compartments after filling, various side ground structures have been proposed. For example, Japanese Utility Model Publication No. 2-19077 (Feather Futon) discloses that when forming a plurality of adjacent small compartments with a gore cloth between a surface material and a lining, at least one side of the gore cloth forming the adjacent small compartments, The two parallel gore cloths having a small interval are provided, and a space between the two parallel gore cloths is a feather feeding pipe insertion chamber, and an opening end of the feather feeding pipe insertion chamber is opened at the periphery of the futon. In a parallel gore cloth, there has been proposed a futon structure in which two or more pipe insertion holes are provided in each of the small compartments so that two or more pipe insertion holes do not face each other (see FIGS. 4 and 5). In addition, each figure corresponds to FIGS. 1 and 2 attached to the above-mentioned publication, and the reference numerals attached also conform to the publication (there is no strict correspondence with other drawings attached to this specification).

[0004] When the structure is abbreviated, (1) in the figure is a dress material, (2) is a lining, and a dress material (1) and a lining (2) are overlapped.
The outer peripheral edges of the outer material (1) and the lining (2) are bound with a marginal cloth (3) of an appropriate width, and a gore cloth is provided between the outer material (1) and the lining (2).
(4) is assembled in a lattice pattern at appropriate intervals in the course of the process to form a small compartment (5). In the binding with the above-mentioned edge cloth (3), the opening end (11) of the feed pipe insertion chamber (8) is opened until the feathers are sealed. At least one side of the small compartment (5) is in contact with the pipe insertion chamber (8) into which the feed pipe (7) is inserted,
A feather feed pipe insertion hole (9) is provided at a position corresponding to each small compartment (5) of the gore cloth (4a), and a feather feed pipe insertion hole (9) is provided in each small compartment (5). A suitable amount of feathers is pneumatically charged through the filling. As shown in FIG. 6 (corresponding to FIG. 3 in the above publication including the reference numerals), the insertion hole is formed as a small hole (36).
In some cases, a cover (37) is provided to close the cover.

In the above manufacturing process, the gore cloth (4) and the front and back linings
To connect (1, 2), for example, a folded portion (6) is provided at the upper and lower ends of the gore cloth, and the folded portion (6) and the front and back linings (1, 2) are stitched together using a thread. Need to be integrated, which requires a lot of man-hours, and also requires some skill for workers.

[0006] In addition, Japanese Utility Model Publication No. 7-42370 (Feather Futon) also discloses that a plurality of small compartments adjacent to each other are formed by a gore cloth between a surface material and a lining and filled with feathers, and are arranged in parallel in one direction. A plurality of gore cloths are extended from one end to the other end of the futon, and upper and lower edges are sewn to a surface material and a lining, thereby forming a gore cloth integrated with a side ground, and intersecting with the gore cloth. One end of the crossed gore cloth in the direction is extended (than the interval width of the through gore cloth), and the (bent) extended portion is overlapped with the gore cloth so that the feather filling pipe can be inserted,
Like the through gore cloth, the upper and lower edges are sewn to the outer fabric and the lining, respectively, to be integrated with the side fabric, and the structure of the feather futon in which the feather filling pipe insertion opening is opened in the through gore cloth in the overlapping portion. It has been proposed (see FIGS. 7 (a) and 7 (b); reference numerals are based on the publication).

According to the proposal, a duvet (21) is provided between a surface material (22) and a lining (23) and has a plurality of through gore cloths (24) extending parallel to the longitudinal direction of the futon; And the crossed gore cloth (25) intersecting in a lattice form, constitutes a small compartment (26). Folds (27, 28) are provided at both upper and lower edges, and the folds are sewn to the outer material (22) and the lining (23) with threads, respectively.
The crossed gore cloth (25) crossing the through gore cloth (24) is provided with folds (29, 30) at both upper and lower edges, and is also sewn to the outer material (22) and the lining (23). One of the edges is sewn to the gore cloth (24) through the outside as a fold (31), and the other edge is bent at the position in contact with the gore cloth (24) to pass through the extension (32). It is in a state of being overlapped with the gore cloth (24). This overlap (3
3) Open through gore cloth (24) with feather filling pipe insertion port (35)
Is provided for each small compartment (26).

According to this structure, the feather is filled with the gore cloth (24A) through the feather filling pipe from one edge (36) of the feather bedding (21) which is kept open without sewing. Two
4A) and the crossed gore cloth (25A, 25B, 25C, 25D) through the overlap (33), insert the tip into the small compartment (26A) and fill a predetermined amount of feather Then, the village end is inserted into the small compartment (26B) through the feather filling pipe insertion port (35), and feathers are filled in the same manner except for the small compartment at the end.

In the above structure, in the manufacturing process, a folded portion is provided at the upper and lower ends of the gore cloth for connection between each gore cloth and the front and back linings, and the folded portion and the front and back linings (22, 26) are formed by using a thread. It is necessary to integrate both by suturing, which requires a lot of man-hours and requires some skill in the work.

Incidentally, using the same structure as described above, the parallel gore cloth and the orthogonal gore cloth, or the through gore cloth and the crossed gore cloth are arranged obliquely to the outer edge of the futon. Such duvets are disclosed in, for example, Japanese Utility Model Registration No. 3028298. The same structure is shown in FIGS. 8A and 8B (the reference numerals are based on the publication).

[0011]

SUMMARY OF THE INVENTION As described above, the present invention requires a skilled worker and requires a large amount of work time to realize the conventional structure proposed to facilitate the feather filling operation. Accordingly, it is an object of the present invention to provide a new method of manufacturing a duvet that has the same structure and function as the above-described structure, but can be manufactured extremely easily with low man-hours.

[0012]

In order to solve the problem, according to the method of the present invention, on one surface of a main gore cloth having a predetermined width and a predetermined length, which is a partition chamber surface, the same predetermined width and a predetermined lattice spacing length are respectively provided at predetermined intervals. The two main gores, which are overlapped with each other in the longitudinal direction and are joined together at one end thereof in the width direction, and the opposite surfaces of the divided screen are opposed to each other and arranged in the same direction. The upper and lower ends of the cloth are overlapped with a band-like material including a thermosetting adhesive layer aligned with the adhesive layer outside, and joined in a line along substantially the center of the band-like material by sewing or the like to form the main gore. The main gore cloth joined by the cloth and the gore cloth including the orthogonal gore cloth is formed as a plurality of small sections adjacent to each other in a continuous lattice with the main gore cloth as one surface, and the main gore cloth and the orthogonal gore cloth are formed at a substantially central portion in the width direction. A belt-like material including a thermosetting adhesive layer at the upper and lower ends of each of the orthogonal gore cloths A flat lattice-shaped frame with the adhesive layers aligned outside and superimposed and joined linearly along the center of the strip by sewing or the like, so that the bonding surfaces of each strip are exposed on the upper and lower surfaces The above-mentioned lattice-like frame body is maintained in a desired shape, and a predetermined front side ground and a back side ground are overlapped and held integrally on the upper and lower surfaces thereof, respectively, and the front side ground and the lattice-like frame body and the back side are directly kept by a thermocompression bonding device. The three members of the ground are adhered in layers at the band-shaped material portion, so that each is at least one location on the partition side except for the filling pipe insertion chamber between the main gore cloth and the small compartment at the periphery. A plurality of sub-compartments adjacent to and adjacent to the filling pipe insertion chamber are provided in a substantially lattice shape, and each sub-compartment has at least a pipe insertion hole communicating with the filling pipe insertion chamber at another pipe insertion hole. After forming one side ground and filling each sub-compartment with feathers, Sealed with appropriate means to complete the duvet by.

In another method, the predetermined width is substantially the same as that of the main gore cloth at each of the predetermined spacing positions, which are the lattice spacings of the small compartments on one surface forming the branch surface of the main gore cloth having the predetermined width and the predetermined length. An orthogonal gore cloth having the same width and a predetermined lattice spacing length plus an extended part is aligned in the longitudinal direction and both are overlapped, and one end of the orthogonal gore cloth is joined along the width direction, and A predetermined length at the other end of the orthogonal gore cloth that branches off from the main gore cloth is extended and held as an extension, and the upper and lower ends of the main gore cloth include a thermosetting adhesive layer. Are aligned with the adhesive layer on the outside and overlapped and joined by linear sewing or the like along the approximate center of the band-shaped material, so that the main gore cloth and the gore cloth including the orthogonal gore cloth are continuous with each other. A plurality of small sections adjacent to each other in a grid are formed, and a thermosetting adhesive layer is formed on upper and lower ends of each of the orthogonal gore cloths. The main gore cloth and the orthogonal gore cloth are bent at substantially the center part in the width direction by linearly sewing and joining the band-like materials including Form a flat lattice-like frame body in which the adhesive surface of the band-like material is exposed on the upper and lower surfaces by folding it in half, and maintaining the lattice-like frame body in a desired shape, with predetermined upper and lower surfaces on the upper and lower surfaces respectively. The ground is superimposed and kept together, and the three members of the front side ground, the grid-shaped frame body and the back side ground are adhered in a layered manner at the strip-shaped material portion by the thermocompression bonding apparatus, and thus the main compartment except for the small compartment at the periphery is removed. Filling pipes for pneumatic pneumatic feeding at the overlapping portion of the gore cloth and the orthogonal gore cloth. After filling the feathers sequentially through the gap, the periphery is sealed by appropriate means to complete the duvet

[0014] In the above method, a filling pipe insertion hole may be provided at a predetermined interval position which is a lattice interval of one of the small compartments forming a branch surface of the main gore cloth having the predetermined width and the predetermined length, and may be placed. At the time of feather filling, each of the small compartments may be filled with feather through the filling pipe insertion hole.

[Operation] In each method, the frame portion of the lattice-like gore cloth which is commonly inside the futon is first formed independently by sewing or the like, so that even a complicated structure can be easily operated. Then, the desired front side ground and the back side ground are overlapped on the upper and lower sides of the flattened frame portion, and the whole is assembled by heat bonding which can be directly mechanized, so that the operation does not require skill and the operation time can be shortened. In this manner, a duvet having an internal structure excellent in known filling workability and function can be obtained by extremely easy work, and the number of steps can be greatly reduced. In addition, a duvet having advantages (aesthetics, hygiene, etc.) by adhesive bonding suitable for a known duvet is obtained.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION

[Embodiment] The present invention will be described below in detail with reference to the drawings with reference to embodiments. FIGS. 1 and 2 are enlarged perspective views of a main part for explaining a manufacturing process of a duvet according to the method of the present invention. FIG. 3 is an enlarged perspective view of a main part of a plane frame for explaining a manufacturing process of another method described later. As described above, there is no strict correspondence between the reference numerals in FIGS. 1 to 3 and the reference numerals in FIGS. 4 to 8 described above.

According to the present invention, for example, a duvet having the same appearance as that shown in FIG. 4 and a filling structure similar to that shown in FIGS. 5 and 6 (the main gore cloths are in close contact with each other) is manufactured. First, the manufacturing process of one of the methods of the present invention will be described in detail with reference to the drawings.

In the present method, in order to manufacture such a futon, first, for example, the partition wall of the small compartment (5) extending in the longitudinal direction is formed, and at the same time, the insertion portion of the feather filling pipe (filling pipe insertion chamber: 7) is formed. A predetermined width to form a gore cloth
A required number of main gore cloths (4A) made of an appropriate cloth material having a predetermined length are prepared. Each main gore cloth requires a pipe insertion hole (4a) at a position corresponding to each of the small compartments (5). In the embodiment, the main gore cloth has a slit shape and is formed in a later step. Of course, at this stage, a slit as a pipe insertion hole (4a) may be formed at a predetermined position of the main gore cloth. Alternatively, as a pipe insertion hole (4a), a small hole of a certain size is provided and a cover piece (37) for closing the small hole.
May be attached by sewing both ends in the longitudinal direction from the predetermined surface side (see FIG. 6).

At one of the surfaces of the main gore cloth (4A), which is a partition chamber surface, at a predetermined interval position for forming a small compartment (5), a predetermined width of substantially the same width as the main gore cloth (4A) is provided. The orthogonal gore cloth (4C), which is slightly longer than the lattice spacing length, is overlapped with their longitudinal directions aligned, and one end of the orthogonal gore cloth (4C) is joined by sewing in the width direction. For the other end of the orthogonal gore cloth (4C), there is no inconvenience even if it is sewn to the same main gore cloth as described above, but usually when it corresponds to the middle part of the futon, it is combined with a single orthogonal gore cloth (4B). Similarly, sewing is performed (see FIG. 1 (a)), and if it becomes the periphery of the futon, it is left as it is, and later, it is sewn and sealed as the periphery.

Subsequently, the upper and lower ends of the two main gore cloths (4A, 4A), which are opposite to each other with the opposite faces of the section screen facing each other and aligned in the same direction, each include a thermosetting adhesive layer. The strips (6) are aligned with the adhesive layer on the outside, overlapped, and joined linearly along the center of the strips (6) by sewing or the like (see FIG. 1 (b)).
The gap between the two main gore cloths (4A, 4A) thus formed is a filling pipe insertion chamber (7) through which a filling pipe for feather pneumatic feeding is inserted.
Becomes As described in detail in Japanese Patent Publication No. 6-49015, the band-like material (6) has a thermosetting (or heat-softening) property on one surface of a band-shaped base cloth made of a nonwoven fabric or the like. Is coated or impregnated, and the surface on the side of the adhesive is covered with a protective tape. Remove the protective tape to prevent dust from attaching after sewing.

With the gore cloth material including the main gore cloth and the orthogonal gore cloth as described above, the connected main gore cloth (filled pipe insertion chamber) is one side of a section and has a continuous and lattice-like shape. A plurality of subsections are formed.

Subsequently, the main gore cloth (4A, 4B) and the orthogonal gore cloth (4C)
Is bent substantially at the center in the width direction and folded in two to form a flat shape, and then includes a thermosetting adhesive layer similar to that described above along each side end of each orthogonal gore cloth (4C). Book strip
(6) is overlapped with the adhesive layer on the outside (exposed as the upper and lower surfaces of the frame), edges are aligned, and joined along a line along substantially the center of the band-shaped material (6) by sewing or the like. In addition, the part (intersection of the frame) that intersects the band material sewn earlier is skipped and only the main side of the section is sewn. Thus, in the end, each strip
A flat lattice frame (1) with the adhesive surface of (6) exposed on the upper and lower surfaces
0) is formed (see FIG. 1 (c)). A belt-like material (6) may be sewn to the upper and lower ends of the orthogonal gore cloth first and then bent to flatten it.

When the pipe insertion hole (4a) is not formed, a slit is formed at each corresponding position of the main gore cloth (4A) at this time. This can be done simply by making a cut in the bent portion of the main gore cloth (4A) from the outside (or more) for each of the small compartments at right angles to the front of the center. Each cut position (slit position) is provided so that the main gore cloths joined to each other do not face each other.

Next, as shown in FIG. 2 (a), the lattice-shaped frame (10) formed through the above-described steps is kept in a predetermined shape as it is, and the upper and lower surfaces thereof are respectively provided with a predetermined front side ground (1) and a rear side. Earth (2)
Are layered together. Then, while keeping this state, the sheet is passed through, for example, a heat-roller-type thermocompression bonding device (not shown) having a sufficient width whose temperature is appropriately controlled. By this heating step, the front side ground (1), the lattice frame (10) and the back side ground
(2) The three members are adhered in layers only at the strip-shaped material portion and are integrally joined. The thermocompression bonding may be performed by a flat plate press method, or may be performed by heating with a suitable heat source along the bonding line and curing by pressing.

In this way, as clearly shown in FIG. 2 (b) in a three-dimensional state, between the main gore cloth (4A, 4A), a filling pipe insertion chamber (7) for pneumatic pneumatic feeding and a peripheral part of the peripheral part are provided. Excluding small compartments,
A side ground (bag body) is formed in which a plurality of small compartments (5) which are adjacent and adjacent to each other at least one of the compartment sides and are adjacent to the filling pipe insertion chamber are provided in a substantially lattice shape. Each small compartment (5) has at least one pipe insertion hole (4a) communicating with the filling pipe insertion chamber (7) without facing other pipe insertion holes (facing the main gore cloth to be paired). Is provided. In the manufacturing process of side lands described above, each sewing operation is limited to the exposed portion, and the bonding process is also mechanized, so that even inexperienced workers can easily obtain uniform side lands.

After that, a duvet is formed through exactly the same steps as in the prior art. That is, feathers are sequentially pneumatically fed into each of the small compartments (5) through the filling pipe insertion chamber (7) using the feather filling pipe and filled in an appropriate amount, and then the peripheral portion is sealed by an appropriate means to thereby provide a duvet. Is completed. In addition, a bag is formed in a form including a sealed small compartment along the filling pipe insertion chamber up to the peripheral portion, and feathers are filled in all the small compartments using a feather filling pipe, and a filling opening is formed. Only the part may be sealed. In any case, in the method of the present invention, since the process of joining the gore cloth to the front side ground and the back side ground is completed by bonding, a duvet can be manufactured with a simple operation, low man-hours, and the price is reduced and the quality is reduced. It leads to conversion. In addition, as a known bonding effect, the product also has the advantages that the appearance of the product has no sewing line, high quality, and high hygiene.

Incidentally, the method of the present invention also has an advantage that the degree of freedom in design is high. In the above description, the case of a rectangular lattice shape is illustrated, but the shape of the plane frame body is bent between the crossed gore cloth portions, sandwiched between the front side ground and the back side ground while maintaining the hexagonal lattice shape, and thermocompression bonded integrally, etc. A duvet made of a hexagonal lattice-shaped small compartment with high designability can be manufactured in the same easy process. In addition, the present invention can also be applied to the manufacture of an oblique lattice-shaped duvet as shown in FIG. 8 mentioned above as a prior art. It can be applied only by deciding.

Next, another embodiment of the method of the present invention will be described. Although the present invention also has the same appearance as that shown in FIG. 4, a duvet having the same structure as that shown in FIGS. 7A and 7B relating to the filling of feathers can be easily obtained. The manufacturing process will be described. First, for example, a required number of main gore cloths (4D) made of an appropriate cloth material having a predetermined width and a predetermined length to form a section extending in the longitudinal direction are prepared. Each main gore cloth is formed with a slit as a pipe insertion hole (4a) at a position corresponding to each of the small compartments. As described above, a small hole and a corresponding covering piece may be provided as the pipe insertion hole. Even if the pipe insertion hole (4a) is not provided, the small compartment can be filled with feathers as described later, but the small compartment can be filled only on one side.

On one side of the main gore cloth (4D), of the small compartments on both sides defined by the main gore cloth, the side to be filled from the pipe insertion hole (4a) (hereinafter referred to as a branch surface). ) At a predetermined interval corresponding to the side length of the small compartment at each location, the width is approximately the same width as the main gore cloth (4D), the length is folded to a predetermined grid interval length, and the length is added to the orthogonal length. The gore cloth (4E) is overlaid on the main gore cloth with the longitudinal direction aligned, and one end of the orthogonal gore cloth (4E) is joined by sewing in the width direction.

The main gore cloth thus processed is sequentially joined to the next main gore cloth at the other end of the orthogonal gore cloth to form a lattice shape. A predetermined length of the tip (the length where the remaining length is the lattice interval) is overlapped with the adjacent main gore cloth (4E) as an extension (4e) to form the pipe insertion hole (4
a) The upper and lower ends of the main gore cloth (4E) (and simultaneously the side ends of the extension (4e)) are covered with a thermosetting adhesive layer.
(6) are aligned with the adhesive layer on the outside, overlapped, and joined in a line along substantially the center of the band-shaped material (6) by sewing. In this way, a plurality of subsections adjacent to each other in a grid form are formed by the gore cloth group including the main gore cloth and the orthogonal gore cloth having substantially the same futon area, and the extended section (4e) of the orthogonal gore cloth (4E) is formed. 7) covers the slit (pipe insertion hole: 4a) of the main gore cloth (4D) to obtain the known internal structure shown in FIG. 7 (b). In addition, the strip material for heat bonding
(6) is similar to the one described above.

Subsequently, the main gore cloth and the orthogonal gore cloth are bent at a substantially central portion in the width direction to be folded in two to form a flat shape, and along the remaining side end of each of the orthogonal gore cloths arranged in a line. The strip (6) containing a thermosetting adhesive layer with the adhesive layer on the outside (exposed as the upper and lower surfaces of the frame), aligning the edges, and placing the strip in the approximate center of the strip (6). It is joined by sewing along a line. In addition, only the main side of the skipped section is sewn at a portion (intersection of the frame) that intersects with the band material (6) sewn earlier. As a result, a flat lattice frame (10 ') in which the bonding surfaces of the strips (6) are exposed on the upper and lower surfaces as shown in FIG. 3 is obtained.

Thereafter, as in the previous invention, the lattice frame
(10 ') is maintained in a predetermined shape, and a predetermined front side ground (1) and a predetermined back side ground (2) are integrally laminated on the upper and lower surfaces, respectively, and passed through a heat roller type thermocompression bonding apparatus while maintaining the state. Then, the band-shaped material portion is heated and adhered. Thus the front side ground (1)
Thus, an integrated bag body is obtained in which the three members of the lattice frame (10 ') and the back side (2) are adhered in layers only at the band-shaped material portion. In the manufacturing process of the bag body (the futon side) described above, since each sewing is limited to the exposed portion and the bonding process is also mechanized, even the inexperienced worker can easily form the uniform futon side as in the previous invention. can get.

Next, each small compartment (5) is filled with feathers. In this bag, orthogonal gore cloth (4E) that branches off from the main gore cloth (4D)
The extended portion (4e) of the tip overlaps the main gore cloth (4D) and opens at both ends only in the direction in which the main gore cloth extends, forming a tunnel-shaped passage section (7 ') through which a feather filling pipe can be inserted. Since both ends of each passage communicate with the continuous small compartments (5, 5), a feather filling pipe can be inserted along one main gore cloth (4D), and the feathers are sequentially passed through each small compartment. Can be filled. After the passage portion (7 ') is filled with feathers, the passage portion (7') is pressed by the feathers which are about to expand, so that the passage portion (7 ') is sealed, so that movement of the feathers between the small compartments is prevented. In the case where the main gore cloth is provided with a slot, feathers can be filled in the small compartments on both sides along the main gore cloth. After filling the feather, the periphery is sealed by an appropriate means to complete the duvet.

In the case of the above-mentioned invention method, as in the previous invention, the process of joining the gore cloth to the front side and the back side is completed by heat bonding, so that the duvet can be manufactured with simple operations and low man-hours, and the cost is low. Quality and quality. Also in the case of this method, the lattice shape can be a hexagonal shape or the like. Further, the present invention can easily be applied to a futon having a shape in which the lattice sides are inclined.

In each of the inventions described above, the gore cloth portion at the middle portion of the futon, which has a complicated structure as described above, is first assembled independently by sewing or the like, and the front side ground and the back side which have been difficult to perform conventionally. The work is easy and the number of man-hours can be reduced because bonding to the ground is performed by heat bonding. It is to be noted that the manufacturing method is such that a duvet having the advantages of the known adhesive sewing and the extremely excellent function can be obtained.

In addition, the present invention provides advantages other than man-hour reduction for the manufacturer. That is, the demand for a duvet having a seasonal product tendency has a large seasonal variation. In the prior art, all the target futon fabrics are prepared in advance and sewn in the order of the back fabric, the middle structural material, and the front fabric, and the man-hour is required, and it is difficult to divide the work. As a result, it was necessary to prepare production equipment and personnel on a large scale in order to cope with periods of heavy demand. However, according to the present invention, a grid-like frame (intermediate structure) that requires a lot of work
A large number of products can be prepared during off-season periods or the like, and a large number of finished products can be supplied quickly and in a timely manner by using heated rollers in response to an overcrowded period. This results in a dramatic increase in the annual factory operation rate, which is very favorable for the manufacturer because it can meet a large demand with a smaller production facility.

[0037]

According to the method of the present invention, the process as described in detail above, that is, a member in which an adhesive layer is exposed on the upper and lower surfaces of the frame in a lattice-like flat frame is first formed separately. Then, a predetermined front side ground and a predetermined back side ground are overlaid on the upper and lower sides of the frame body, and they are heated and bonded as they are to form a bag-like side ground. In order to manufacture futons, a duvet with a known structure equivalent to a well-known structure that is excellent in preventing the movement of filled feathers can be obtained with much easier work and lower man-hours compared to conventional products, leading to product price reduction and industrial Is very significant. As a secondary effect, a hygienic duvet with an excellent appearance can be obtained by adhesive bonding, and a futon with various lattice shapes can be easily obtained, thereby increasing the degree of freedom in design.

[Brief description of the drawings]

FIGS. 1A, 1B, and 1C are enlarged perspective views each showing a main part of a blanket during a manufacturing process for explaining the method of the present invention.

FIGS. 2 (a) and 2 (b) are enlarged perspective views showing a main part of a duvet during a manufacturing process for explaining the method of the present invention.

FIG. 3 is an enlarged perspective view showing a main part of a duvet during a manufacturing process according to another method of the present invention.

FIG. 4 is a plan view showing a known duvet structure.

FIG. 5 is an enlarged perspective view of a main part showing an internal structure of the same duvet.

FIG. 6 is an enlarged perspective view of a main part showing a different internal structure of a known duvet.

FIG. 7 is a plan view showing a duvet having a different known structure (a),
FIG. 3 is an enlarged perspective view of a main part showing an internal structure.

8 (a) and 8 (b) are plan views illustrating a duvet in which a lattice direction is oblique.

[Explanation of symbols]

(1)… front side ground, (5)… small compartment, (2)
… Lining, (6)… strip (adhesive layer),
(4A) ... main gore cloth, (7) ... filling pipe insertion chamber, (4B) ... main gore cloth, (7 ') ... filling pipe insertion gap, (4D) ... main gore cloth, (10) ... lattice frame Body, (4a)… Pipe insertion hole, (20,30)…
Lattice frame. (4C) ... orthogonal gore cloth, (4E) ... orthogonal gore cloth, (4e) ...
Extensions,

Claims (3)

[Claims] 1. A predetermined width and a predetermined length of a main gore cloth (4A) having a same width and a predetermined width at a predetermined interval position on one surface side as a partition chamber surface.
Orthogonal gore cloth (4C) having a predetermined lattice spacing length is overlapped in the longitudinal direction, and one end of the orthogonal gore cloth (4C) is joined along the width direction. The upper and lower ends of the two main gore cloths (4A, 4A) that are aligned and stacked are aligned and stacked with the adhesive layer on the outside and the belt-shaped material (6) including the thermosetting adhesive layer. ) Are joined linearly along a substantially central portion by sewing or the like, and the main gore cloth joined by the gore cloth including the main gore cloth and the orthogonal gore cloth is adjacent to each other to form a continuous grid. A plurality of small sections are formed, and the main gore cloth (4A, 4A) and the orthogonal gore cloth (4C) are bent at substantially the center in the width direction and folded in two, and the upper and lower ends of each of the orthogonal gore cloth (4C) are formed. A belt-like material (6) including a thermosetting adhesive layer is placed on top of the adhesive layer with the adhesive layer on the outside and overlapped, and joined in a line along substantially the center of the belt-like material (6) by sewing or the like. Up and down the adhesive side of the material A flat lattice-shaped frame (10) is formed, and the lattice-shaped frame (10) is maintained in a desired shape, and a predetermined front side ground (1) and a predetermined back side ground (2) are respectively provided on upper and lower surfaces thereof. The front side ground (1) and the lattice-shaped frame (10) and the back side ground (2) are heat-bonded in a layered manner at the band-shaped material portion by a thermocompression bonding device or the like. Except for the filling pipe insertion chamber (7) for feather pneumatic feeding between the main gore cloth and the small division chamber at the peripheral edge, at least one section of the division side is in contact with and adjacent to the filling pipe insertion chamber. A plurality of small compartments (5) are provided in a substantially lattice shape, and each small compartment has at least one pipe insertion hole (4a) communicating with the filling pipe insertion chamber in another pipe insertion hole (4a). A method of manufacturing a duvet comprising forming side lands, filling each small compartment (5) with feathers using a feather filling pipe, and then sealing the peripheral portion by appropriate means. . 2. A predetermined width of the main gore cloth (4D) having a width substantially equal to the width of the main gore cloth at each of predetermined spacing positions, which are lattice intervals of the small compartments (5) on one side forming a branch surface of the main gore cloth (4D) having a predetermined width and a predetermined length. Orthogonal gore cloth (4E) with the length of the grid spacing plus the extension (4e)
One end of the orthogonal gore cloth (4E) is joined by sewing or the like in the width direction, and the other end of the orthogonal gore cloth extending from the main gore cloth (4D) is extended. A predetermined length of the tip is superimposed on and held by the main gore cloth (4D) as an extension (4e), and a belt-like material including a thermosetting adhesive layer is attached to each of the upper and lower ends of the main gore cloth (4D). Are arranged in a line along substantially the center of the band-shaped material and joined by sewing or the like so that the main gore cloth and the gore cloth group including the orthogonal gore cloth are connected to each other in a lattice form. A plurality of small sections adjacent to the orthogonal gore cloth (4E), and a band-shaped material (6) including a thermosetting adhesive layer is arranged on each of the upper and lower ends of the orthogonal gore cloth (4E) with the adhesive layer outside and aligned. The main gore cloth (4D) and the orthogonal gore cloth (4E) are bent at substantially the center in the width direction and folded in two to be folded in two along a line along substantially the center of the material (6) by sewing or the like. (6) A flat lattice-shaped frame (20) exposed on the lower surface is formed, and the lattice-shaped frame (20) is maintained in a desired shape, and a predetermined front side ground (1) and a predetermined back side ground (2) ) Are stacked and kept together, and the three members of the front side ground (1), the grid frame (20) and the back side ground (2) are heat-bonded in a layered manner at the band-shaped material portion by a thermocompression bonding device or the like, whereby A plurality of adjacent and continuous small compartments (5) having a filling pipe insertion gap (7 ') for pneumatic pneumatic feeding at the overlapping portion of the main gore cloth and the orthogonal gore cloth except for the small compartment at the peripheral edge
Are formed in a substantially lattice shape, and each small compartment (5) is filled with feathers through a filling pipe insertion gap (7 ′) using a feather filling pipe, and then the peripheral edge is sealed by appropriate means. A method of manufacturing a duvet comprising stopping. 3. A filling pipe insertion hole (4a) is provided at a predetermined interval position which is a lattice interval of a small compartment (5) on one surface forming a branch surface of a main gore cloth (4D) having a predetermined width and a predetermined length, In the vicinity of the filling pipe insertion hole of the main gore cloth (4D), an orthogonal gore cloth having a length substantially equal to the width of the main gore cloth at a predetermined lattice spacing length and an extended portion (4e) added at the predetermined interval position. (4E) is aligned in the longitudinal direction, the two are overlapped, one end of the orthogonal gore cloth is joined by sewing or the like along the width direction, and the orthogonal gore cloth (4E) that branches off from the main gore cloth and extends A predetermined length at the other end is an extended portion (4e), and the filling pipe insertion hole (4
a) Gore cloth (4D)
Material including a thermosetting adhesive layer at each of the upper and lower ends of the belt (6)
Are aligned with the adhesive layer on the outside, overlapped, and joined linearly along the substantially center of the band-shaped material (6) by sewing or the like, whereby the gore cloth group including the main gore cloth and the orthogonal gore cloth A plurality of small sections adjacent to each other in a grid shape are formed continuously with each other, and a band-shaped material (6) including a thermosetting adhesive layer is provided on each of the upper and lower ends of the orthogonal gore cloth (4E) with the adhesive layer facing outward. The main gore cloth (4D) and the orthogonal gore cloth (4E) are bent at substantially the center in the width direction, and are joined in a line along substantially the center of the strip-shaped material (6). A flat lattice-shaped frame (30) is formed by folding and exposing the adhesive surface of the band-shaped material on the upper and lower surfaces, and the lattice-shaped frame (30) is maintained in a desired shape and a predetermined shape is provided on each of the upper and lower surfaces. The front side ground (1) and the back side ground (2) are overlapped and kept together, and the three sides of the front side ground (1), the lattice frame (30), and the back side ground (2) are layered by a thermocompression bonding device or the like. Glued to the strip at Te, filling pipe insertion gap for feeding feathers care overlapping portion of the small compartment except for orthogonal to the main gusset fabric gore fabric periphery
A plurality of adjacent and continuous sub-compartments (5) having (7 ′) are formed in a substantially grid-like side pattern, and a filling pipe insertion gap (7) is inserted into each sub-compartment (5) using a feather-filling pipe. )), A method of manufacturing a duvet comprising the steps of sequentially filling the feathers and sealing the peripheral portion by an appropriate means.