Removal device

Abstract

To provide a removing device for automatically removing a foam and a tubular film adhered to the outside of a cylindrical part in a funnel.SOLUTION: To provide a removing device for removing a foam and a tubular film adhered to the outside of a cylindrical part in a funnel having a conical part and the cylindrical part connected to the conical part. The removing device includes a conical part holding means for holding the conical part of the funnel, a cylindrical part pinching means for pinching the cylindrical part of the funnel, and a first moving means for relatively moving the conical part holding means holding the conical part and the cylindrical part pinching means pinching the cylindrical part along the cylindrical part so as to be separated from each other.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a removal device for removing foam and tubular film adhering to the outside of the barrel of a funnel. [Background technology]

[0002] In automobile headrests, armrests, etc., integrally molded skin insert products are widely used, in which a foaming material is injected into a skin in which the insert is placed, and the skin and insert are foam-molded as a single unit. Patent Document 1 discloses a method for manufacturing an integrally molded skin insert product, in which a skin having an injection slit is prepared, a tubular film is inserted into the injection slit, a funnel is inserted into the tubular film, the foaming material is injected into the skin through the funnel, and the funnel is removed from the injection slit. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 2847647 Summary of the Invention [Problem to be solved by the invention]

[0004] When the funnel is removed from the injection slit, the foam and tubular film may adhere to the outside of the barrel of the funnel. In order to reuse the funnel, it is desirable to remove the foam and tubular film that have adhered to the outside of the barrel of the funnel.

[0005] The present disclosure provides a removal device that automatically removes foam and tubular film that adheres to the outside of the barrel of a funnel. [Means for solving the problem]

[0006] A removal device according to one embodiment of the present disclosure is a removal device for removing foam and tubular film adhering to the outside of a cylindrical portion of a funnel having a conical portion and a cylindrical portion connected to the conical portion. The removal device includes a conical portion holding means for holding the conical portion of the funnel, a cylindrical portion clamping means for clamping the cylindrical portion of the funnel, and a first moving means for relatively moving the conical portion holding means holding the conical portion and the cylindrical portion clamping means clamping the cylindrical portion along the cylindrical portion so that they move away from each other. [Effects of the Invention]

[0007] According to the present disclosure, a removal device can be provided that automatically removes foam and tubular film adhering to the outside of the cylindrical portion of a funnel. [Brief explanation of the drawings]

[0008] [Figure 1] A diagram illustrating a method for manufacturing an integrated skin molded product using a funnel. [Figure 2] FIG. 1 is a front view and a side view showing the appearance of a removal device. [Figure 3] 10A and 10B are top views showing the cylindrical portion clamping means in an open state and a closed state. [Figure 4] 10A and 10B are diagrams illustrating the operation of the removal device, particularly the operation of removing foam and tubular film adhering to the outside of the cylindrical portion of the funnel. [Figure 5] 1 shows the operation of the removal device, particularly the operation of removing foam stuck to the inside of the funnel. [Figure 6] Continuing from FIG. 5, a diagram showing the operation of the removal device, particularly the operation of removing foam adhering to the inside of the funnel. DETAILED DESCRIPTION OF THE INVENTION

[0009] As shown in FIG. 1, the skin 1 is formed in a bag shape and has a hole 2 and an injection slit 4 penetrating the skin 1. The hole 2 is a hole for allowing the stay 3 to protrude outside the skin 1. The injection slit 4 is a slit for injecting the foaming material into the skin 1. A funnel 6 is prepared to inject the foaming material into the skin 1. The funnel 6 has a conical portion 7 and a cylindrical portion 8 connected to the conical portion 7. A tubular film 5 is also prepared to prevent the foaming material from adhering to the skin 1 near the injection slit 4. The tubular film 5 is inserted into the injection slit 4. The funnel 6 is inserted into the tubular film 5. The foaming material is injected into the interior of the skin 1 through the funnel 6 and the tubular film 5. After the foaming material has been injected, the funnel 6 is removed from the skin 1. The funnel 6 is accompanied by a foam 9 adhering to the inside of the funnel 6 and the foam 9 and the tubular film 5 adhering to the outside of the cylindrical portion 8.

[0010] In order to reuse the funnel 6, it is desirable to remove the foam 9 adhering to the inside of the funnel 6 and the foam 9 and tubular film 5 adhering to the outside of the cylindrical portion 8. Furthermore, in order to increase productivity, it is desirable to automate the work required for such removal.

[0011] 2, the removal device 100 includes a frame 10, a funnel holding unit 20, a film removing unit 30, a foam removing unit 40, a rod inserting unit 50, and a control unit 60. In this embodiment, the removal device 100 removes the foam 9 adhering to the inside of the funnel 6, and also removes the foam 9 and the tubular film 5 adhering to the outside of the cylindrical portion 8.

[0012] The frame 10 includes a base frame 11, a vertical frame 12 fixed to the base frame 11, and a top frame 13 fixed to the vertical frame 12. The frame 10 supports a funnel holding unit 20, a film removing unit 30, a foam removing unit 40, and a bar inserting unit 50.

[0013] The funnel holding unit 20 includes a first rail 21, a first slider 22, a movable claw actuator 23, and a movable claw 24. The first rail 21 is fixed to the vertical frame 12 and extends in the X direction. The first slider 22 is disposed on the first rail 21 so as to be movable in the X direction. The movable claw actuator 23 is fixed on the first slider 22 and is movable between a first retracted position 20a and a first working position 20b. The movable claw actuator 23 is an actuator such as an air cylinder, a hydraulic cylinder, a motor, or the like, and drives the movable claw 24 in the X direction. The movable claw 24 includes a first movable claw 24a and a second movable claw 24b. When the first movable claw 24a and the second movable claw 24b approach each other, the conical portion 7 of the funnel 6 is held by the first movable claw 24a and the second movable claw 24b. When the first movable claw 24a and the second movable claw 24b move away from each other, the conical portion 7 of the funnel 6 is released from its hold.

[0014] The film removing unit 30 includes a second rail 31, a second slider 32, a first vertical actuator 33, a first vertical actuator shaft 34, a lever actuator 35, and a lever 36. The second rail 31 is fixed to the base frame 11 and extends in the Y direction. The second slider 32 is disposed on the second rail 31 so as to be movable in the Y direction. The first vertical actuator 33 is fixed on the second slider 32. The first vertical actuator 33 is an air cylinder, a hydraulic cylinder, a motor, or other actuator. By moving the first vertical actuator shaft 34 in the Z direction, the lever 36 moves in the Z direction. The lever actuator 35 is fixed on the first vertical actuator shaft 34. The lever actuator 35 is an air cylinder, a hydraulic cylinder, a motor, or other actuator. The lever 36 is configured to clamp the cylindrical portion 8 of the funnel 6.

[0015] The foam removal unit 40 includes a second vertical actuator 41, a second vertical actuator shaft 42, a rotating stator 43, a rotating rotor 44, a needle actuator 45, and a needle 46. The second vertical actuator 41 is fixed to the top frame 13. The second vertical actuator 41 is an air cylinder, a hydraulic cylinder, a motor, or other actuator, and moves the second vertical actuator shaft 42 in the Z direction to move the needle actuator 45 in the Z direction. The rotating stator 43 is fixed to the second vertical actuator shaft 42. The rotating rotor 44 is rotatable about a Z axis relative to the rotating stator 43. The rotating stator 43 rotates the rotating rotor 44 about the Z axis, thereby rotating the needle actuator 45 about the Z axis. The needle actuator 45 is fixed to the rotating rotor 44 and drives the needle 46. In this embodiment, the needle actuator 45 can selectively assume a retracted state in which the needle 46 is housed inside, and a protruding state in which the needle 46 is protruding outside. The needle 46 includes a first needle 46a and a second needle 46b. The needle actuator 45 moves the first needle 46a on a first axis ax and moves the second needle 46b on a second axis bx. In this embodiment, the first axis ax intersects with the Z direction. The second axis bx intersects with the Z direction and the first axis ax.

[0016] The bar insertion unit 50 includes a third rail 51, a third slider 52, a bar actuator 53, and a bar 54. The third rail 51 is fixed to the vertical frame 12 and extends in the X direction. The third slider 52 is disposed on the third rail 51 so as to be movable in the X direction. The bar actuator 53 is fixed to the third slider 52 and is movable between a third retracted position 50a and a third working position 50b. The bar actuator 53 is an actuator such as an air cylinder, a hydraulic cylinder, a motor, or the like, and drives the bar 54 in the Z direction. The bar 54 extends along the Z direction and has an outer diameter smaller than the inner diameter of the cylindrical portion 8 of the funnel 6.

[0017] The control unit 60 includes a processor and a memory. The memory stores a program for sequentially driving the funnel holding unit 20, the film removing unit 30, the foam removing unit 40, and the bar inserting unit 50. The processor executes this program to sequentially drive the funnel holding unit 20, the film removing unit 30, the foam removing unit 40, and the bar inserting unit 50.

[0018] As shown in FIG. 3, the lever 36 of the film removing unit 30 includes a first clamping lever 36a extending in the Y direction and a second clamping lever 36b extending in the Y direction. The first clamping lever 36a and the second clamping lever 36b can be selectively placed in an open state (FIG. 3(a)) or a closed state (FIG. 3(b)). The first clamping lever 36a has a first semicircular recess 37a. The second clamping lever 36b has a second semicircular recess 37b. When the first clamping lever 36a and the second clamping lever 36b are closed, the first semicircular recess 37a and the second semicircular recess 37b form a circular hole 37c. The inner diameter of the circular hole 37c is set to match the outer diameter of the tip side of the cylindrical portion 8 of the funnel 6. The cylindrical portion 8 of the funnel 6 has a base that connects to the conical portion 7 and a tip on the opposite side. The outer diameter of the cylindrical portion 8 may be constant from the base to the tip, or may taper from the base to the tip. In this embodiment, the outer diameter of the cylindrical portion 8 tapers from the base to the tip. Because the inner diameter of the circular hole 37c is matched to the outer diameter of the tip side of the cylindrical portion 8, the first clamping lever 36a and the second clamping lever 36b are pressed against the cylindrical portion 8 at the base of the cylindrical portion 8 as they descend.

[0019] The film removing unit 30 further includes a first peeling bar 38a disposed below the first clamping lever 36a and a second peeling bar 38b disposed below the second clamping lever 36b. When the first clamping lever 36a and the second clamping lever 36b are open (see FIG. 3A), the first peeling bar 38a is located below the first semicircular recess 37a, and the second peeling bar 38b is located below the second semicircular recess 37b. When the first clamping lever 36a and the second clamping lever 36b are closed (see FIG. 3B), the first peeling bar 38a and the second peeling bar 38b are located away from the circular hole 37c so as not to block the circular hole 37c.

[0020] In this embodiment, the first peeling bar 38a is fixed to the second clamping lever 36b. The second peeling bar 38b is fixed to the first clamping lever 36a. Specifically, the first peeling bar 38a includes a first main bar 38ay extending in the Y direction and a first connection bar 38ax connected to the first main bar 38ay and extending in the X direction. The first connection bar 38ax is fixed to the second clamping lever 36b by a first fastening member 38af. The second peeling bar 38b includes a second main bar 38by extending in the Y direction and a second connection bar 38bx connected to the second main bar 38by and extending in the X direction. The second connection bar 38bx is fixed to the first clamping lever 36a by a second fastening member 38bf. As the first and second clamping levers 36a, 36b open, the first and second peeling bars 38a, 38b move toward each other. As the first and second clamping levers 36a, 36b close, the first and second peeling bars 38a, 38b move away from each other.

[0021] Next, the operation of the removal device 100 to remove the foam and tubular film 5 adhering to the outside of the cylindrical portion 8 of the funnel 6 will be described. This operation is achieved by the control unit 60 driving the funnel holding unit 20 and the film removing unit 30. The control unit 60 positions the funnel holding unit 20 at the first working position 20b, the film removing unit 30 at the second working position 30b, and the bar insertion unit 50 at the third retracted position 50a.

[0022] As shown in FIG. 4(a), the funnel holding unit 20 holds the conical portion 7 of the funnel 6. Specifically, the funnel holding unit 20 clamps the conical portion 7 of the funnel 6 by bringing the first movable claw 24a and the second movable claw 24b closer to each other. The funnel 6 is accompanied by a foam and a tubular film 5. The film removing unit 30 maintains the first clamping lever 36a and the second clamping lever 36b in an open state.

[0023] 4(b), the film removing unit 30 closes the first clamping lever 36a and the second clamping lever 36b (see arrow A1). The first semicircular recess 37a and the second semicircular recess 37b surround the cylindrical portion 8 of the funnel 6. The first peeling bar 38a and the second peeling bar 38b move to positions away from the first semicircular recess 37a and the second semicircular recess 37b.

[0024] As shown in FIG. 4(c), the film removing unit 30 moves the first clamping lever 36a and the second clamping lever 36b along the cylindrical portion 8 away from the funnel holding unit 20 (see arrow A2). Specifically, the first vertical actuator 33 moves the first vertical actuator shaft 34 downward. The first clamping lever 36a and the second clamping lever 36b press the tubular film 5 downward, peeling it off from the funnel 6. The tubular film 5 either falls downward or, as shown in FIG. 4(c), adheres to the first clamping lever 36a or the second clamping lever 36b.

[0025] As shown in FIG. 4(d), the film removing unit 30 opens the first clamping lever 36a and the second clamping lever 36b (see arrow A3). Accordingly, the first peeling bar 38a moves below the first semicircular recess 37a, and the second peeling bar 38b moves below the second semicircular recess 37b. The first peeling bar 38a and the second peeling bar 38b press the tubular film 5 attached to the first clamping lever 36a or the second clamping lever 36b horizontally, peeling the tubular film 5 from the first clamping lever 36a or the second clamping lever 36b. The tubular film 5 falls downward.

[0026] The removal device 100 continues to remove the foam 9 adhering to the inside of the funnel 6. This operation is realized by the control unit 60 driving the funnel holding unit 20, the foam removing unit 40, and the bar inserting unit 50. The control unit 60 continues to position the funnel holding unit 20 at the first working position 20b, the film removing unit 30 at the second retracted position 30a, and the bar inserting unit 50 at the third working position 50b.

[0027] As shown in Figure 5(a), the funnel holding unit 20 maintains the cone portion 7 of the funnel 6. The foam removal unit 40 is located above the funnel 6. The bar insertion unit 50 is located below the funnel 6.

[0028] As shown in FIG. 5(b), the foam removal unit 40 descends so that the needle actuator 45 approaches the conical portion 7 of the funnel 6 (see arrow A4). The needle actuator 45 then protrudes the first needle 46a and the second needle 46b to the outside (see arrow A5). To avoid damaging the inside of the funnel 6, it is desirable to adjust the extent to which the first needle 46a and the second needle 46b protrude so that they do not reach the inside of the funnel 6. The first needle 46a and the second needle 46b pierce the foam 9 adhering to the inside of the funnel 6.

[0029] As shown in FIG. 5(c) and FIG. 6(a), the rotating stator 43 rotates the rotating rotor 44, thereby rotating the needle actuator 45 (see arrows A6 and A8). When the needle actuator 45 rotates, the rod actuator 53 moves the rod 54 inside the cylindrical portion 8 toward the conical portion 7 (see arrows A7 and A9). "During rotation" means that the period when the rod actuator 53 moves the rod 54 at least partially overlaps with the period when the needle actuator 45 rotates. The rotation of the needle actuator 45 and the pressure of the rod 54 cause the foam 9 to peel off from the funnel 6. In this embodiment, the rotation angle is approximately 180 degrees, but is not limited to this.

[0030] 6(b), during or after the rotation of the needle actuator 45, the foam removal unit 40 raises the needle actuator 45 so that it moves away from the funnel 6 (see arrow A10). In addition, the rod actuator 53 lowers the rod 54 so that it is removed from the cylindrical portion 8 of the funnel 6 (see arrow A11). After this, the funnel holding unit 20 opens the first movable claw 24a and the second movable claw 24b to release the funnel 6 from its hold so that the funnel 6 can be reused.

[0031] 6(c), the needle material actuator 45 accommodates the first needle material 46a and the second needle material 46b within the needle material actuator 45 (see arrow A12). As a result, the first needle material 46a and the second needle material 46b come out of the foam 9, causing the foam 9 to fall downward (see arrow A13).

[0032] As described above, this embodiment provides a removal device 100 for removing foam and tubular film 5 adhering to the outside of a cylindrical portion 8 of a funnel 6 that includes a conical portion 7 and a cylindrical portion 8 connected to the conical portion 7. The removal device 100 includes a conical portion holding means for holding the conical portion 7 of the funnel 6. The movable claw actuator 23 and the movable claw 24 are an example of a conical portion holding means. The removal device 100 includes a cylindrical portion clamping means for clamping the cylindrical portion 8 of the funnel 6. The lever actuator 35 and the lever 36 are an example of a cylindrical portion clamping means. The removal device 100 includes a first moving means for relatively moving the conical portion holding means, which holds the conical portion 7, and the cylindrical portion clamping means, which clamps the cylindrical portion 8, along the cylindrical portion 8 so that they move away from each other. The first vertical actuator 33 and the first vertical actuator shaft 34 are an example of a first moving means.

[0033] This embodiment also provides a removal device 100 for removing foam 9 adhering to the inside of a funnel 6, which includes a conical portion 7 and a cylindrical portion 8 connected to the conical portion 7. The removal device 100 includes a holding means for holding the funnel 6. The movable claw actuator 23 and the movable claw 24 are examples of the holding means. The removal device 100 also includes a piercing means for piercing the foam 9 adhering to the inside of the funnel 6, held by the holding means, with a first needle 46a and a second needle 46b from the conical portion 7 side of the funnel 6. The piercing means moves the first needle 46a along a first axis ax and moves the second needle 46b along a second axis bx intersecting the first axis ax. The needle actuator 45 is an example of the piercing means. The removal device 100 also includes a rotation means for rotating the piercing means that pierces the foam 9 with the first needle 46a and the second needle 46b. The rotating stator 43 and the rotating rotor 44 are an example of a rotating means. The removal device 100 includes a rod inserting means for inserting a rod 54 from the cylindrical portion 8 side of the funnel 6 into the inside of the cylindrical portion 8. The rod actuator 53 is an example of a rod inserting means.

[0034] The removal device 100 further includes a second moving means for relatively moving the piercing means and the holding means so that the piercing means moves away from the funnel 6 during or after the piercing means is rotated by the rotating means. The second vertical actuator 41 and the second vertical actuator shaft 42 are an example of the second moving means.

[0035] The removing device 100 further includes a film removing means for removing the tubular film 5 adhering to the outside of the cylindrical portion 8 of the funnel 6. The film removing unit 30 is an example of the film removing means.

[0036] Although the present disclosure has been described above with reference to the embodiment, the present disclosure is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention. In particular, the multiple modifications described in this specification can be arbitrarily combined as necessary.

[0037] For example, in the above embodiment, the foam removal unit 40 includes both the first needle material 46a and the second needle material 46b. However, the present invention is not limited to this. The foam removal unit 40 may include only one of the first needle material 46a and the second needle material 46b. For example, even if the foam removal unit 40 includes the first needle material 46a but not the second needle material 46b, the foam 9 can be removed from the funnel 6. Because the first axis ax is inclined with respect to the rotation axis (Z direction) of the rotating rotor 44, the first needle material 46a can rotate the foam 9 within the funnel 6. Furthermore, because the first axis ax is inclined with respect to the movement direction (Z direction) of the second vertical actuator 41, the first needle material 46a can lift the foam 9 from the funnel 6. [Explanation of symbols]

[0038] 100: Removal device, 10: Frame, 20: Funnel holding unit, 30: Film removal unit, 40: Foam removal unit, 50: Bar insertion unit, 60: Control unit 60, 23: Movable jaw actuator, 24a: First movable jaw, 24b: Second movable jaw, 33: First vertical actuator, 34: First vertical actuator shaft, 35: Lever actuator, 36: Lever, 41: Second vertical actuator, 42: Second vertical actuator shaft, 43: Rotating stator, 44: Rotating rotor, 45: Needle actuator, 46a: First needle, 46b: Second needle, 53: Bar actuator, 54: Bar

Claims

1. A removal device for removing foam and tubular film adhering to the outside of a cylindrical portion of a funnel having a conical portion and a cylindrical portion connected to the conical portion, comprising: a cone portion holding means for holding the cone portion of the funnel; a cylindrical portion clamping means for clamping the cylindrical portion of the funnel; a first moving means for relatively moving the conical portion holding means, which holds the conical portion, and the cylindrical portion clamping means, which clamps the cylindrical portion, along the cylindrical portion so as to move them away from each other; A removal device comprising:

2. the cylindrical portion clamping means includes a first clamping lever and a second clamping lever; 2. The removal device according to claim 1, wherein the first clamping lever has a first semicircular recess, the second clamping lever has a second semicircular recess, and when the first clamping lever and the second clamping lever are closed, the first semicircular recess and the second semicircular recess surround the cylindrical portion.

3. The tape further includes a first peel bar disposed below the first clamping lever and a second peel bar disposed below the second clamping lever, 3. The removal device according to claim 2, wherein when the first clamping lever and the second clamping lever are open, the first peeling bar is positioned below the first semicircular recess and the second peeling bar is positioned below the second semicircular recess.

4. the first peeling bar is fixed to the second pinching lever; the second peeling bar is fixed to the first pinching lever; 4. The removal device according to claim 3, wherein the first and second peeling bars move closer to each other when the first and second clamping levers open, and the first and second peeling bars move farther apart when the first and second clamping levers close.

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