Formed resin structure manufacturing device

Abstract

To provide a formed resin structure manufacturing device having large contact area between an aggregate and both sides of a drawing section even if thickness of molten resin aggregate is uncertain.SOLUTION: A formed resin structure manufacturing device has a drawing section 50 to draw molten resin into a bottom surface side of a cooling tank 30, and a rail material 90 to which both ends of the drawing section 50 are connected. The drawing section 50 is formed so that a first rotor 51 is separated away from a second rotor 52. One end of the first rotor 51 and that of the second rotor 52 are fitted to a first rail material 91 provided on one end side of the drawing section 50, and the other end of the first rotor 51 and that of the second rotor 52 are fitted to a second rail material 92 provided on the other end side. At least either one of the first rotor 51 and the second rotor 52 can change orientation in horizontal direction by separating movement on one end side along the first rail material 91 from movement on the other end side along the second rail material 92 so that state of the first rotor 51 and the second rotor 52 can be changed between parallel state and non-parallel state.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an apparatus for manufacturing knitted resin structures that can be used for mattresses, cushioning, pillows, household items, and the like. [Background technology]

[0002] Knitted resin structures, which have a three-dimensional network structure in which a large number of resins are randomly entangled and partially heat-fused, are used in mattresses, etc. Knitted resin structures can be obtained by cooling an aggregate of molten resins. For example, Patent Document 1 discloses a method for producing a three-dimensional network structure by extruding molten thermoplastic resin downward from multiple nozzles, allowing it to fall naturally between a pair of partially submerged belt conveyors, and withdrawing it at a speed slower than the falling speed, in which the distance between the pair of belt conveyors is narrower than the width of the bundle of extruded molten resin, and both sides or one side of the bundle of molten resin comes into contact with the belt conveyors before the belt conveyors are submerged. Patent document 2 discloses a network structure loop forming device comprising opposing chutes, water supply sections that supply water to the surfaces of the chutes, and width setting plates that are arranged opposite each other and intersect the longitudinal direction of the chutes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-241264 [Patent Document 2] International Publication No. 2012 / 035736 DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0004] As described in Patent Documents 1 and 2, the molten resin descends between a pair of retractors (such as belt conveyors) and is drawn downward by the retractors. When manufacturing an knitted resin structure whose thickness does not change depending on the location, such as for a mattress, the thickness of the molten resin assembly is constant, so it is easy for it to come into contact with the retractors on both sides. However, when manufacturing a product whose thickness changes depending on the location, such as for a pillow with varying heights, the thickness of the molten resin assembly is inconsistent, so there are places where it only comes into contact with the retractors on one side, and the surface molding may differ slightly depending on the location. Therefore, the present invention aims to provide an apparatus for manufacturing knitted resin structures that can increase the contact area between the assembly and both sides of the retraction section even when the thickness of the molten resin assembly is indefinite, such as when manufacturing knitted resin structures for pillow use, whose thickness varies depending on the location. [Means for solving the problem]

[0005] The knitted resin structure manufacturing apparatus of the present invention as set forth in claim 1 comprises a supply section 10 for supplying molten resin, a linearizing section 20 for linearizing the molten resin supplied from the supply section 10 by letting it flow out from holes, a cooling tank 30 in which a cooling liquid for cooling the linearized molten resin is stored, a lead-in section 50 disposed in the cooling tank 30 and rotating in contact with the molten resin to sequentially draw the molten resin toward the bottom side of the cooling tank 30, and rail members 90 disposed on either side of the lead-in section 50 and connected to both ends of the lead-in section 50, the lead-in section 50 comprising a first rotating body 51 and a second rotating body 52 spaced apart from each other and having horizontal rotation axes, and the rail member 90 is disposed at one end of the lead-in section 50. The rotary member 91 is made up of a first rail member 91 provided on one end side of the retraction section 50, and a second rail member 92 provided on the other end side of the retraction section 50, and one end of the first rotary body 51 and one end of the second rotary body 52 are attached to the first rail member 91, and the other end of the first rotary body 51 and the other end of the second rotary body 52 are attached to the second rail member 92, and at least one of the first rotary body 51 and the second rotary body 52 is capable of changing its horizontal orientation by separating the movement of one end side along the first rail member 91 from the movement of the other end side along the second rail member 92, and is characterized in that it is variable between a state in which the first rotary body 51 and the second rotary body 52 are parallel and a state in which the first rotary body 51 and the second rotary body 52 are not parallel.

[0006] The present invention described in claim 2 is characterized in that, in the knitted resin structure manufacturing apparatus described in claim 1, one end and the other end of the first rotating body 51 or the second rotating body 52, whose orientation can be changed, are freely rotatable in the horizontal direction.

[0007] The present invention described in claim 3 is characterized in that, in the knitted resin structure manufacturing apparatus described in claim 1 or claim 2, it is provided with a rotatable rod member 80 consisting of a first rod member 81 and a second rod member 83, which is arranged in parallel with the first rotating body 51 and the second rotating body 52, and a coupling 100 which connects the first rod member 81 and the second rod member 83, and a rail member 90 which is connected to the rod member 80 and rotates with the rotation of the rod member 80, and the first rotating body 51 or the second rotating body 52, which can change its direction, moves along the rail member 90 as the rod member 80 rotates, and by setting the first rod member 81 and the second rod member 83 to a state where they are not connected by the coupling 100, the movement of one end of the first rotating body 51 or the second rotating body 52, which can change its direction, along the first rail member 91 and the movement of the other end of the first rotating body 51 or the second rotating body 52 along the second rail member 92 can be separated. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide an apparatus for manufacturing knitted resin structures that can increase the contact area between the assembly and the retraction portion even when the thickness of the molten resin assembly is inconstant, such as when manufacturing knitted resin structures for pillow use, whose thickness varies depending on the location. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a block diagram of an apparatus for manufacturing a knitted resin structure according to an embodiment of the present invention; [Figure 2] FIG. [Figure 3] A comparison of contact points of the molten resin aggregate passing through the same intake section DETAILED DESCRIPTION OF THE INVENTION

[0010] The knitted resin structure manufacturing apparatus according to the first embodiment of the present invention comprises a supply section that supplies molten resin, a linearizing section that linearizes the molten resin supplied from the supply section by letting it flow out through a hole, a cooling tank that stores a cooling liquid for cooling the linearized molten resin, and a retraction section that is arranged in the cooling tank and rotates in contact with the molten resin to sequentially retract the molten resin toward the bottom side of the cooling tank, and the retraction section is characterized in that it comprises a first rotating body and a second rotating body that are spaced apart and have horizontal rotation axes, and is variable between a state in which the first rotating body and the second rotating body are parallel and a state in which the first rotating body and the second rotating body are not parallel. According to this embodiment, the speed at which the draw-in portion draws in the aggregate of molten resin can be prevented from varying depending on the location, and variation in the surface condition of the woven resin structure formed when the molten resin is cooled can be eliminated.

[0011] The second embodiment of the present invention is an apparatus for manufacturing a woven resin structure according to the first embodiment, in which the orientation of either the first rotating body or the second rotating body is fixed, and only the orientation of the other rotating body in the horizontal direction can be changed. According to this embodiment, the device configuration can be simplified compared to when both the first rotating body and the second rotating body are positionally changeable.

[0012] A third embodiment of the present invention is a knitted resin structure manufacturing apparatus according to the second embodiment, which is provided with a rotatable first rod member and a second rod member provided in parallel with the first rotating body and the second rotating body, a first rail member having a screw groove and connected perpendicularly to the first rod member and rotating with the rotation of the first rod member, and a second rail member having a screw groove and connected perpendicularly to the second rod member and rotating with the rotation of the second rod member, and one end of the first rotating body or the second rotating body, which has a fixed orientation, is attached to the first rail member without being fitted into the screw groove, and the orientation of the first rail member is changeable. One end of the rotating body or the second rotating body is attached by fitting into the screw groove, and the other end of the first rotating body or the second rotating body, whose orientation is fixed, is attached to the second rail material without fitting into the screw groove, and the other end of the first rotating body or the second rotating body, whose orientation is changeable, is attached by fitting into the screw groove, and the one end of the first rotating body or the second rotating body attached by fitting into the screw groove moves along the first rail material by rotation of the first rod member, and the other end of the first rotating body or the second rotating body attached by fitting into the screw groove moves along the first rail material by rotation of the second rod member. According to this embodiment, the angle between the first rotating body and the second rotating body can be easily changed.

[0013] In the fourth embodiment of the present invention, in the knitted resin structure manufacturing apparatus according to the third embodiment, one end and the other end of the first rotating body or the second rotating body, whose orientation can be changed, are freely rotatable in the horizontal direction. According to this embodiment, one end or the other end of the first rotating body or the second rotating body automatically rotates to an appropriate angle during movement, allowing for smooth movement.

[0014] A fifth embodiment of the present invention is an apparatus for manufacturing a knitted resin structure according to the third or fourth embodiment, further comprising a coupling for connecting the first rod member and the second rod member. According to this embodiment, when the first rod member and the second rod member are connected by a coupling, the spacing can be easily adjusted by moving at least one of the first rotating body or the second rotating body in parallel, and when the coupling is disconnected, the first rotating body or the second rotating body can be oriented at an angle. [Example]

[0015] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a diagram showing the configuration of a knitted resin structure manufacturing apparatus. The knitted resin structure manufacturing apparatus according to an embodiment of the present invention continuously forms knitted resin structures 2 having a three-dimensional network-like structure in which a large number of resins are randomly entangled and partially heat-welded by pouring molten resin in a linear form and then immersing the linear molten resin aggregate 1 in a liquid such as water to cool it. The completed knitted resin structure 2 is used as a mattress, pillow, cushion, or the like.

[0016] The knitted resin structure manufacturing apparatus includes a supply section 10 that supplies molten resin, a linearizing section 20 that linearizes the molten resin, a cooling tank 30 that stores a cooling liquid that cools the linearized molten resin, a guider section 40 through which a linear aggregate of molten resin 1 flows down from the linearizing section 20 toward the cooling tank 30, a pull-in section 50 that is arranged in the cooling tank 30 and rotates while in contact with the aggregate of molten resin 1, thereby sequentially pulling the aggregate of molten resin 1 toward the bottom side of the cooling tank 30, and a delivery section 60 that sends the knitted resin structure 2 out of the cooling tank 30.

[0017] The supply unit 10 melts and kneads the thermoplastic resin at a predetermined temperature to form a molten resin, and extrudes the molten resin at a predetermined extrusion speed to supply it to the linearizing unit 20 . As the thermoplastic resin, for example, polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polytetrafluoroethylene, acrylonitrile butadiene styrene resin, etc. may be used alone or in combination.

[0018] The linearizing unit 20 has an inlet at the top for receiving the molten resin extruded from the supply unit 10, and an outlet at the bottom for letting the received molten resin out. The outlet has multiple small holes. The molten resin supplied from the supply unit 10 flows out of the small holes and becomes linear. The linear molten resin flowing out from each small hole forms an aggregate 1 and flows down toward the cooling tank 30.

[0019] In the cooling tank 30, an inlet section 50 and an outlet section 60 are arranged. The lead-in section 50 is disposed at a position where the assembly 1 that has passed through the guider section 40 flows down into the cooling tank 30. The lead-in section 50 has a pair of a first rotor 51 and a second rotor 52 that are arranged facing each other. The first rotor 51 and the second rotor 52 are arranged in parallel at a distance from each other, and the assembly 1 passes through the gap between the first rotor 51 and the second rotor 52. The assembly 1 that has reached the lead-in section 50 is drawn sequentially toward the bottom side of the cooling tank 30 while coming into contact with at least one of the first rotor 51 and the second rotor 52. The first rotating body 51 and the second rotating body 52 each have two rotating rollers, one above the other, and a belt stretched over the rotating rollers, and are configured so that the belt rotates like an endless track. Note that the first rotating body 51 and the second rotating body 52 can also be configured without a belt.

[0020] The delivery section 60 has, for example, an inclined conveyor. The assembly 1 (woven resin structure 2) drawn into the bottom side of the cooling tank 30 is lifted diagonally upward by the inclined conveyor and delivered out of the cooling tank 30. Note that instead of the inclined conveyor, a rotating body such as a roller can be used to lift the woven resin structure 2 and deliver it out of the cooling tank 30.

[0021] FIG. 2 is a top view of the retraction section 50. FIG. A mounting frame 70 is provided around the retraction section 50, and a rod member 80 is rotatably provided on the outside of the mounting frame 70 in parallel with the first rotating body 51 and the second rotating body 52. ​​Furthermore, a pair of rail members 90 are provided perpendicular to the rod member 80 on the inside of the mounting frame 70, sandwiching the retraction section 50 therebetween. The rod member 80 is composed of a first rod member 81 located at one end of the retraction section 50 and a second rod member 83 located at the other end of the retraction section 50, connected in series via a coupling 100. The first rod member 81 has a first handle 82 at its tip. The second rod member 83 has a second handle 84 at its tip.

[0022] The pair of rail members 90 comprises a first rail member 91 to which one end of the retractable portion 50 is connected, and a second rail member 92 to which the other end of the retractable portion 50 is connected. One end of the first rail member 91 is connected to the mounting frame 70, and the other end is connected to the first rod member 81. A screw groove is formed in the first rail member 91, and one end of the first rotating body 51 is attached to the first rail member 91 via a first mounting member 53 that is not fitted into the screw groove, and one end of the second rotating body 52 is attached to the first rail member 91 via a second mounting member 54 that is fitted into the screw groove. In addition, a swivel connecting member is used to connect one end of the second rotating body 52 to the second mounting member 54, allowing one end of the second rotating body 52 to be freely rotatable in the horizontal direction. One end of the second rail member 92 is connected to the mounting frame 70, and the other end is connected to the second rod member 83. A screw groove is formed in the second rail member 92, and the other end of the first rotating body 51 is attached to the second rail member 92 via a first mounting member 53 that is not fitted into the screw groove, and the other end of the second rotating body 52 is attached to the second rail member 92 via a second mounting member 54 that is fitted into the screw groove. A swivel connecting member is used to connect the other end of the second rotating body 52 to the second mounting member 54, allowing the other end of the second rotating body 52 to be freely rotatable in the horizontal direction.

[0023] When the first handle 82 or the second handle 84 is turned while the first rod member 81 and the second rod member 83 are connected by the coupling 100, the entire rod member 80 rotates, which in turn rotates the pair of rail members 90, causing the second rotating body 52, both ends of which are fitted into the screw grooves, to move parallel to the rail members 90. On the other hand, the position of the first rotating body 51, both ends of which are not fitted into the screw grooves, does not change. 2(a) and 2(b), the distance between the first rotating body 51 and the second rotating body 52 can be changed. Note that FIG. 2(a) shows a state in which the distance between the first rotating body 51 and the second rotating body 52 is at its maximum, and FIG. 2(b) shows a state in which the distance between the first rotating body 51 and the second rotating body 52 is at its minimum.

[0024] Furthermore, when the first handle 82 is turned with the coupling 100 disengaged, the first rod member 81 rotates, causing the first rail member 91 to rotate accordingly, and one end of the second rotor 52, which is fitted in the screw groove, moves along the first rail member 91. Meanwhile, the position of the one end of the first rotor 51 that is not fitted in the screw groove remains unchanged. Furthermore, because the second rod member 83 does not rotate even when the first handle 82 is turned, the position of the other end of the second rotor 52 also remains unchanged. As a result, as shown in FIG. 2(c), the second rotor 52 is oriented obliquely relative to the first rotor 51, and the distance between the first rotor 51 and the second rotor 52 can be increased toward the other end. Note that FIG. 2(c) illustrates a state in which the distance between the first rotor 51 and the second rotor 52 at the other end is at its maximum. Furthermore, when the second handle 84 is turned with the coupling 100 disengaged, the second rod member 83 rotates, and the second rail member 92 also rotates, causing the other end of the second rotor 52, which is engaged with the thread groove, to move along the second rail member 92. Meanwhile, the position of the other end of the first rotor 51, which is not engaged with the thread groove, remains unchanged. Furthermore, because the first rod member 81 does not rotate even when the second handle 84 is turned, the position of one end of the second rotor 52 also remains unchanged. As a result, as shown in FIG. 2(d), the second rotor 52 is oriented obliquely relative to the first rotor 51, and the distance between the first rotor 51 and the second rotor 52 can be increased toward the one end. Note that FIG. 2(d) illustrates a state in which the distance between the first rotor 51 and the second rotor 52 at the one end is at its maximum. Furthermore, if the end of the second rotating body 52 were fixedly connected to the second mounting member 54, for example, when attempting to move only one end of the second rotating body 52, the other end of the second rotating body 52 may also move, or one end of the second rotating body 52 may not move smoothly. However, in this embodiment, a swivel connecting member is used to connect the end of the second rotating body 52 to the second mounting member 54, so that as the second rotating body 52 moves, the end of the second rotating body 52 automatically rotates to an appropriate angle, thereby preventing the other end from moving and allowing the one end to move smoothly.

[0025] In this way, a coupling 100 is provided to connect the first rod member 81 and the second rod member 83, and by turning the first handle 82 or the second handle 84 while the first rod member 81 and the second rod member 83 are connected by the coupling 100, the second rotating body 52 can be moved parallel to the first rotating body 51, making it possible to easily adjust the spacing, and by turning the first handle 82 or the second handle 84 while the coupling 100 is disconnected, the second rotating body 52 can be oriented diagonally relative to the first rotating body 51.

[0026] Figure 3 is a diagram comparing the contact points of the assembly 1 passing through the retraction section 50, where Figure 3(a) shows a state in which the first rotating body 51 and the second rotating body 52 are parallel, and Figure 3(b) shows a state in which the second rotating body 52 is tilted relative to the first rotating body 51. When attempting to manufacture a knitted resin structure 2 to be used as a pillow with varying heights, the thickness of the molten resin assembly 1 is not constant. Conventionally, the distance between the first rotating body 51 and the second rotating body 52 is set to match the maximum thickness, but since the first rotating body 51 and the second rotating body 52 are always parallel, as shown in Figure 3(a), there are some points where they contact both sides of the aggregate 1, but there are also many points where they only contact one side of the aggregate 1. As a result, the speed at which the retraction section 50 retracts the aggregate 1 varies slightly depending on the location, and the surface condition of the knitted resin structure 2 may change. On the other hand, the knitted resin structure manufacturing apparatus of this embodiment can be changed between a state in which the first rotating body 51 and the second rotating body 52 are parallel to each other and a state in which the first rotating body 51 and the second rotating body 52 are not parallel to each other, and the second rotating body 52 can be made oblique to the first rotating body 51. Therefore, as shown in Figure 3(b), the number of points of contact with both sides of the assembly 1 increases, which prevents the speed at which the pull-in part 50 pulls in the assembly 1 from varying depending on the location, and eliminates variations in the surface condition of the knitted resin structure 2.

[0027] In addition, the knitted resin structure manufacturing apparatus can be configured so that both the first rotating body 51 and the second rotating body 52 are movable, but as in this embodiment, the first rotating body 51 is fixed and the second rotating body 52 is movable, that is, one of the first rotating body 51 and the second rotating body 52 is fixed and only the position of the other is changeable, thereby simplifying the apparatus configuration. [Explanation of symbols]

[0028] 1 aggregate 2-knit resin structure 10 Supply section 20 Linearized part 30 Cooling tank 40 Guider Department 50 Retraction section 51 First Rotating Body 52 Second Rotating Body 53 First mounting material 54 Second mounting material 60 Transmission Unit 70 Mounting frame 80 Bar member 81 First rod member 82 First Handle 83 Second rod member 84 Second Handle 90 Rail material 91 First Rail Material 92 Second rail material 100 Coupling

Claims

1. a supply unit that supplies molten resin; a linearizing unit that linearizes the molten resin supplied from the supply unit by causing the molten resin to flow out of holes; a cooling tank in which a cooling liquid for cooling the linear molten resin is stored; a drawing unit that is disposed in the cooling tank and rotates while in contact with the molten resin to draw the molten resin sequentially toward the bottom side of the cooling tank; rail members provided on either side of the retractable portion and connected to both ends of the retractable portion; The retraction section is configured by separating a first rotating body and a second rotating body whose rotation axis is horizontal, the rail member includes a first rail member provided on one end side of the retraction portion and a second rail member provided on the other end side of the retraction portion, One end of the first rotating body and one end of the second rotating body are attached to the first rail member, The other end of the first rotating body and the other end of the second rotating body are attached to the second rail member, At least one of the first rotating body and the second rotating body is capable of changing its horizontal orientation by separating movement of one end side along the first rail material from movement of the other end side along the second rail material, An apparatus for manufacturing a knitted resin structure, characterized in that the first rotating body and the second rotating body can be changed between a state in which they are parallel and a state in which they are not parallel.

2. 2. The apparatus for manufacturing a knitted resin structure according to claim 1, wherein one end and the other end of the first rotating body or the second rotating body whose orientation can be changed are rotatable in a horizontal direction.

3. a rotatable rod member provided in parallel with the first rotor and the second rotor, the rod member comprising a first rod member and a second rod member; a coupling that connects the first rod member and the second rod member, the rail member is connected to the rod member and rotates in accordance with the rotation of the rod member; the first rotating body or the second rotating body, the orientation of which can be changed, moves along the rail member by rotation of the rod member; The apparatus for manufacturing a woven resin structure according to claim 1 or claim 2, characterized in that by disengaging the first rod member and the second rod member from each other by the coupling, the movement of one end of the first rotating body or the second rotating body, which can change its orientation, along the first rail material and the movement of the other end of the first rotating body along the second rail material can be carried out separately.

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