Hot air vent oven device

Abstract

We propose a hot air ventilated oven device that can stably heat a laminate to be heated, which consists of a ventilated layer and a non-ventilated layer, and can reduce the time and cost required to manufacture a soundproofing material made of the laminate to be heated. [Solution] This hot air ventilated oven device is equipped with a hot air heating unit 2 on a support surface portion 21 against which the outermost ventilated layer of the laminate to be heated abuts, and a plurality of nozzles 22a for ejecting hot air and a plurality of outlets 23a for discharging hot air are arranged adjacent to each other. With this configuration, the hot air ejected from the nozzles 22a enters the ventilated layer, hits the non-ventilated layer, and is discharged from the outlets 23a. By passing the hot air in the thickness direction of the ventilated layer in this way, the ventilated layer and the non-ventilated layer can be heated stably. Since the ventilated layer and the non-ventilated layer can be heated in a laminated state in this way, the time and cost required for manufacturing can be reduced.

Description

Technical Field

[0001] The present invention relates to a hot air ventilation oven device that heats a heated laminate in which a ventilation layer and a non-ventilation layer are laminated, by hot air.

Background Art

[0002] Sound insulators (silencers) for enhancing the sound insulation performance inside a vehicle are used in automobiles. As such a sound insulator, for example, a configuration in which a plurality of non-woven fabric layers made of non-woven fabric and a breathable film (or breathable sheet) having breathability are laminated has been proposed. Patent Document 1 proposes a method for manufacturing a sound insulator in which such a non-woven fabric layer and a breathable film are laminated. In this manufacturing method, in a state where the non-woven fabric layer and the breathable film are overlapped, they are heated by hot air, and in the heated state, they are press-processed to manufacture a sound insulator having a desired form. Here, since the sound insulator is composed of a breathable material such as a non-woven fabric layer and a breathable film, in the conventional manufacturing method, all layers can be heated by blowing hot air from one side surface and penetrating in the plate thickness direction. Further, Patent Document 1 discloses a method for manufacturing a sound insulator using a breathable core material and a non-breathable skin material, in which the core material and the skin material are separately heated and then overlapped and press-processed (paragraphs 0002 to 0004 of Patent Document 1).

[0003] On the other hand, Patent Document 2 proposes the sound insulator formed by laminating a felt layer and a non-ventilation layer. This conventional configuration can exhibit excellent sound insulation performance due to the sound insulation performance of the non-ventilation layer and the sound absorption performance of the felt layer. Further, Patent Document 2 also proposes a sound insulator having a three-layer structure in which the felt layer, the non-ventilation layer, and the felt layer are laminated. Since such a conventional configuration has high sound insulation performance, it can be suitably used for dash silencers, floor silencers, partition silencers, etc. of automobiles.

Prior Art Documents

Patent Documents

[0004] [Patent Document 1] Japanese Patent Application Publication No. 6-320559 [Patent Document 2] Re-tabled publication No. 2018 / 180887 [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] The soundproofing material described in Patent Document 2 has a structure in which a breathable felt layer and a non-breathable layer are laminated. As a manufacturing method, as mentioned above, a method can be applied in which the felt layer and the non-breathable layer are heated separately and then overlapped and pressed. This is because the non-breathable layer cannot allow hot air to pass through, so when the felt layer and the non-breathable layer are heated with hot air while they are overlapped, it is difficult to heat the boundary between the two layers sufficiently and stably to the interior. If the layers are pressed while they are not heated sufficiently, there is a risk of delamination at the boundary. For these reasons, in the process of manufacturing a soundproofing material made by laminating a felt layer and a non-breathable layer, it is necessary to heat the two layers separately, which tends to complicate the manufacturing process and increase the time and cost required for manufacturing.

[0006] The present invention proposes a hot air ventilated oven device that can stably heat a laminate to be heated, which consists of a ventilated layer and a non-ventilated layer, and can reduce the time and cost required to manufacture a soundproofing material produced from the laminate to be heated. [Means for solving the problem]

[0007] The present invention relates to a hot air ventilated oven device that heats a flat plate-shaped laminate to be heated, in which a breathable layer and a non-breathable layer are laminated, and at least one of the outermost layers is made of the breathable layer, by blowing hot air onto the outermost breathable layer to allow air to circulate, and is characterized in that the hot air heating means has a support surface portion to which the outer surface of the outermost breathable layer abuts, and the support surface portion has a plurality of nozzles for ejecting the hot air toward the outermost breathable layer and a plurality of outlets for discharging the hot air that has passed through the breathable layer, arranged adjacent to each other.

[0008] In this configuration, the laminate to be heated is positioned with the outermost ventilated layer in contact with the support surface, and hot air is ejected from the nozzle on the support surface, thereby heating the outermost ventilated layer and the non-ventilated layer overlapping it. More specifically, the hot air ejected from the nozzle enters and moves through the outermost ventilated layer, hits the non-ventilated layer and bounces back, and is discharged from the outlet adjacent to the nozzle. In this way, the hot air permeates the outermost ventilated layer in the thickness direction, directly heating the ventilated layer, and the hot air also directly heats the non-ventilated layer when it hits it. Here, in the configuration of the present invention, since the nozzle and the outlet are arranged adjacent to each other, a stable flow of hot air is generated from the nozzle, passing through the ventilated layer in the thickness direction and being discharged to the outlet, thereby stably and easily heating the ventilated layer and the non-ventilated layer. In addition, by bringing the outermost ventilated layer into contact with the support surface, the hot air ejected from the nozzle can be reliably and stably introduced into the ventilated layer, further improving the heating effect between the ventilated and non-ventilated layers.

[0009] As described above, with the configuration of the present invention, the laminated state of the breathable layer and the non-breathable layer (the laminate to be heated) can be stably heated to a desired temperature. Therefore, by pressing after heating, a molded product (corresponding to the aforementioned soundproofing body) can be formed in which the breathable layer and the non-breathable layer are stably bonded. Furthermore, in the molded product formed in this way, the occurrence of defects such as delamination at the boundary between the breathable layer and the non-breathable layer is suppressed. Moreover, with this configuration, since the breathable layer and the non-breathable layer can be heated together, manufacturing time and cost can be significantly reduced compared to conventional methods in which they are heated separately.

[0010] In the hot air vent oven device of the present invention described above, the nozzle and the outlet each have a long slit shape, and the nozzle and the outlet are arranged alternately on the support surface in a direction perpendicular to the longitudinal direction. Here, the longitudinal direction refers to the longitudinal direction of the nozzle and the outlet.

[0011] In this configuration, multiple flows of hot air are generated in a direction perpendicular to the longitudinal direction of the slit shape, passing from the nozzle to the outlet in the thickness direction of the ventilation layer, so that the ventilation layer and the non-ventilated layer of the heated laminate can be heated substantially uniformly in the planar direction.

[0012] In the hot air vent oven apparatus of the present invention described above, a configuration is proposed in which the hot air heating means comprises an ejection gas passage connected to each nozzle and an exhaust gas passage connected to each outlet.

[0013] In this configuration, hot air can be supplied stably from each nozzle, and the hot air that has passed through the ventilation layer can be stably discharged from each outlet, thereby creating an even more stable flow of hot air passing through the ventilation layer.

[0014] In the hot air vent oven apparatus of the present invention described above, a configuration is proposed in which two hot air heating means are provided, and the two hot air heating means are arranged so that their support surfaces face each other. Here, the two hot air heating means may be arranged so that their support surfaces always face each other, or they may be arranged so that their support surfaces face each other only when heating the laminate to be heated.

[0015] In such a configuration, for example, it can be applied to heating a laminate to be heated in which a non-permeable layer is sandwiched between permeable layers, and both permeable layers and the non-permeable layer can be heated stably. [Effects of the Invention]

[0016] According to the hot air ventilated oven apparatus of the present invention, the ventilated layer and the non-ventilated layer of the laminate to be heated can be stably heated to a desired temperature, and compared to conventional methods in which the ventilated layer and the non-ventilated layer are heated separately, manufacturing time and manufacturing costs can be significantly reduced. [Brief explanation of the drawing]

[0017] [Figure 1] This is a schematic diagram showing the hot air vent oven device 1 of this embodiment. [Figure 2](A) Plan view, (B) one side view, and (C) the other side view of the hot air heating body 2 that constitutes the hot air ventilation oven device 1. [Figure 3] It is a cross-sectional view taken along the line X-X in Fig. 2. [Figure 4] It is a cross-sectional view taken along the line Y-Y in Fig. 2. [Figure 5] It is a perspective view showing the table portion 11 that constitutes the hot air heating body 2. [Figure 6] (A) Cross-sectional view showing the heated laminate 51, and (B) exploded perspective view of the heated laminate 51. [Figure 7] It is an explanatory diagram showing a mode of heating the heated laminate 51. [Figure 8] It is an explanatory diagram showing a mode of heating the heated laminate 51 in a configuration of another example. [Embodiment for Carrying Out the Invention]

[0018] Examples embodying the present invention will be described using the accompanying drawings. As shown in Fig. 1, the hot air ventilation oven device 1 of this embodiment includes upper and lower hot air heating bodies 2, 2, and heats the heated laminate 51 disposed between the hot air heating bodies 2, 2. Here, the heated laminate 51 is applied to a soundproof body (such as a dash silencer) arranged in the interior of an automobile by being heated to a predetermined temperature in the hot air ventilation oven device 1 and then being formed into a desired shape by press working.

[0019] As shown in Figure 6, the heat-treated laminate 51 of this embodiment is composed of two felt layers 52 and 54 made of sheet-like felt and a sheet layer 53 made of a rubber-based sheet, with the felt layers 52 and 54 arranged so as to sandwich the sheet layer 53 in the thickness direction. In this embodiment, the felt layers 52 and 54 arranged on both sides of the sheet layer 53 have different weights. These felt layers 52 and 54 are breathable, while the sheet layer 53 is not. The soundproofing body molded from this heat-treated laminate 51 has excellent soundproofing performance due to the sound absorption performance of the front and back felt layers 52 and 54 and the sound insulation performance of the sheet layer 53. In this embodiment, the thickness of the felt layers 52 and 54 is 10 to 20 mm, the thickness of the sheet layer 53 is 2 to 5 mm, and the thickness of the heat-treated laminate 51 is approximately 40 mm.

[0020] The hot air vent oven device 1 heats the laminate to be heated 51 by hot air ejected from a hot air heating unit 2, and includes a heating furnace 4 for heating the hot air and a blower 3 for supplying the hot air to the hot air heating unit 2. It also includes a supply pipe 6 for supplying the hot air heated in the heating furnace 4 to the hot air heating unit 2 and a discharge pipe 5 for discharging the hot air used in the hot air heating unit 2, with the supply pipe 6 and the discharge pipe 5 being connected via the heating furnace 4 and the blower 3. Thus, the hot air vent oven device 1 of this embodiment includes a hot air circulation means composed of the blower 3, heating furnace 4, discharge pipe 5, and supply pipe 6, which circulates the hot air supplied to the hot air heating unit 2. Furthermore, the hot air circulation means includes a replenishment means (not shown) for replenishing the hot air lost due to use in the hot air heating unit 2, enabling a stable supply of hot air to the hot air heating unit 2 at a desired flow rate. Furthermore, the hot air vent oven device 1 is equipped with control means for driving and controlling the heating furnace 4 and the blower 3. By controlling the heating furnace 4, this control means can adjust the temperature of the hot air supplied to the hot air heating unit 2, and by controlling the blower 3, it can adjust the flow rate (flow velocity) of the hot air supplied to the hot air heating unit 2.

[0021] In this embodiment, the hot air vent oven device 1 has the hot air circulation means connected to the upper and lower hot air heating units 2, respectively. At least one of the upper and lower hot air heating units 2, 2 is movable in the horizontal direction, and the upper hot air heating unit 2 is movable in the vertical direction. By controlling this horizontal movement, the upper and lower hot air heating units 2, 2 can be repositioned between positions facing each other and positions offset horizontally. Furthermore, by controlling the vertical movement of the upper hot air heating unit 2, the position of the hot air heating unit 2 can be repositioned between a position in contact with the heated stack 51 placed on the lower hot air heating unit 2 and a position spaced upward from the heated stack 51. The hot air vent oven device 1 is equipped with control means for repositioning the hot air heating units 2 in this way.

[0022] Next, the hot air heating unit 2, which is the main component of the present invention, will be described. As shown in Figure 2, the hot air heating unit 2 comprises a rectangular table section 11 (see Figure 5) and a housing section 12 on which the table section 11 is arranged. The table section 11 is arranged in the housing section 12 such that a rectangular support surface section 21 is exposed to the outside. The table section 11 has elongated slit-shaped ejection holes 22 formed along one side edge of the support surface section 21, and elongated slit-shaped discharge holes 23 formed parallel to the ejection holes 22, arranged alternately at predetermined intervals in a direction perpendicular to the side edge. Multiple adjacent ejection holes 22 and discharge holes 23 are provided in this manner. Here, the perpendicular direction is the same as the direction perpendicular to the longitudinal direction of the ejection holes 22 (and discharge holes 23).

[0023] As shown in Figure 3, the ejection hole 22 is provided penetrating the table portion 11 in the thickness direction, with an outlet 22a opening in the support surface portion 21 of the table portion 11 and an inlet 22b opening on the lower surface of the table portion 11 (the surface opposite to the support surface portion 21). On the other hand, as shown in Figures 4 and 5, the discharge hole 23 is formed in the table portion 11 at a predetermined depth, with an outlet 23a opening in the support surface portion 21 and an outlet 23b opening on the side surface of the discharge hole 23 on one end in the longitudinal direction. In this way, the discharge hole 23 does not open on the lower surface of the table portion 11 (does not penetrate in the thickness direction), and the outlet 23a of the support surface portion 21 and the outlet 23b on one side surface are in communication. In this embodiment, the ejection hole 22a and the outlet 23a are formed to be the same length.

[0024] As shown in Figures 3 and 4, the housing portion 12, with the table portion 11 installed, has a sealed supply air area 15 in which the lower surface of the table portion 11 (the surface on which the inlet 22b opens) is exposed, and a sealed discharge air area 16 in which one side surface of the table portion 11 (the surface on which the outlet 23b opens) is exposed. The supply air area 15 is connected to the supply pipe 6 which is connected to one side surface of the housing portion 12, and communicates with the outside only through the supply pipe 6 and the ejection hole 22 of the table portion 11. The discharge air area 16 is connected to the discharge pipe 5 which is connected to the other side surface of the housing portion 12, and communicates with the outside only through the discharge pipe 5 and the discharge hole 23 of the table portion 11.

[0025] In this hot air heating unit 2, the hot air supplied from the supply pipe 6 to the supply air area 15 enters the outlets 22b of the table section 11 into the outlets 222 and is ejected from the outlets 22a of the outlets 22. The hot air that flows into the outlets 23a of the table section 11 into the outlets 23b enters the discharge air area 16 and is discharged from the discharge pipe 5 through the discharge air area 16.

[0026] Next, we will describe how the laminate to be heated 51 is heated using the hot air vent oven device 1 of this embodiment. With the upper and lower hot air heating units 2, 2 separated, the laminate to be heated 51 is placed on the support surface 21 of the lower hot air heating unit 2. At this time, the laminate to be heated 51 may be placed on the support surface 21 with the felt layers 52, 54 and the sheet layer 53 already laminated (state of the laminate to be heated 51), or the felt layers 52, 54 and the sheet layer 53 may be placed on the support surface 21 in the order of lamination.

[0027] After placing the laminate to be heated 51 on the lower support surface 21, the upper hot air heating unit 2 is moved downward to reposition and hold the support surface 21 of the upper hot air heating unit 2 in contact with the upper surface of the laminate to be heated 51. In this state, the support surface 21 of the upper hot air heating unit 2 comes into contact with the upper surface (upper felt layer 52) of the laminate to be heated 51, and the support surface 21 of the lower hot air heating unit 2 comes into contact with the lower surface (lower felt layer 54) of the laminate to be heated 51.

[0028] In the above state, by driving the hot air circulation means connected to the upper and lower hot air heating units 2, 2 respectively, hot air heated to a predetermined temperature in the heating furnaces 4, 4 is supplied to each hot air heating unit 2, 2 through the supply pipes 6, 6. In each hot air heating unit 2, as shown in Figure 7, the hot air that flows from the supply pipes 6 into the supply air area 15 is ejected from each nozzle 22a through each ejection hole 22 of the table section 11. The hot air ejected from the nozzle 22a enters and proceeds through the felt layers 52, 54 that are in contact with the support surface section 21. Here, since the laminate to be heated 51 is in contact with the support surface section 21, the hot air ejected from the nozzle 22a easily enters the felt layers 52, 54. Furthermore, since the ejection holes 22 are formed to penetrate through the table section 11 in the thickness direction, the hot air that has passed through the ejection holes 22 is ejected from the nozzle 22a along the thickness direction. As a result, the hot air ejected from the nozzle 22a enters and travels through the thickness direction of the felt layers 52 and 54, and when it reaches the sheet layer 53, it hits the sheet layer 53, bounces back, and travels in the opposite direction. This hot air traveling in the opposite direction passes through the felt layers 52 and 54 and flows into the outlet 23a of the support surface 21. Here, a suction force from the blower 3 acts on the outlet 23a via the discharge hole 23 and the discharge air area 16, so the hot air that has passed through the felt layers 52 and 54 in the thickness direction as described above flows into the outlet 23a and is discharged from the discharge hole 23 through the discharge air area 16 to the discharge pipe 5. The hot air discharged into the discharge pipe 5 is then supplied again to the hot air heating unit 2 via the heating furnace 4 by the blower 3.

[0029] By passing hot air through the felt layers 52 and 54 of the laminate to be heated 51 in the thickness direction, the felt layers 52 and 54 can be heated, and the sheet layer 53 can also be heated when the hot air hits it. By generating this flow of hot air within the upper and lower felt layers 52 and 54, the entire laminate to be heated 51 can be sufficiently heated to the interior. Here, by controlling the drive of the blower 3, the flow rate of hot air supplied to the hot air heating unit 2 is controlled so that the hot air ejected from each nozzle 22a travels through the felt layers 52 and 54, hits the sheet layer 53, and bounces back. Then, the suction force generated through the discharge pipe 5 by the drive of the blower 3 allows the hot air bounced off the sheet layer 53 to be discharged from each outlet 23a. In this way, the drive control of the blower 3 ensures that the hot air is stably circulated between the hot air heating unit 2 and the hot air circulation means. Furthermore, by controlling the heating furnace 4, a stable supply of hot air at a predetermined temperature is ensured to the hot air heating unit 2. As a result, the laminate to be heated 51 can be stably and reliably heated to the desired temperature by the hot air heating unit 2. For example, in this embodiment, in order to heat the laminate to be heated 51, which is about 40 mm thick, to a desired temperature (130 to 180 degrees), it is heated by a heating furnace 4 with hot air at a predetermined temperature (180 to 240 degrees).

[0030] As described above, the hot air vent oven device 1 of this embodiment allows the felt layers 52, 54 and the sheet layer 53 constituting the laminated body 51 to be heated to a desired temperature in a stable manner. Therefore, a desired soundproofing body (not shown) can be stably formed by pressing it after heating. In the soundproofing body thus formed, delamination at the boundary between the felt layers 52, 54 and the sheet layer 53 is suppressed. Thus, with the configuration of this embodiment, since the felt layers 52, 54 and the sheet layer 53 can be heated to a desired temperature while they are laminated, there is no need to heat each layer separately as in the conventional configuration described above, and the time and cost required for the manufacturing process of the soundproofing body can be significantly reduced.

[0031] In the embodiment described above, the hot air heating unit 2 corresponds to the hot air heating means according to the present invention. The supply air area 15 of the housing 12 and the ejection holes 22 of the table 11 correspond to the ejection gas passage according to the present invention, and the discharge air area 16 of the housing 12 and the discharge holes 23 of the table 11 correspond to the discharge gas passage according to the present invention.

[0032] The present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. For example, the dimensions and shapes in the embodiments described above can be modified as appropriate.

[0033] In the above-described embodiment, the upper and lower table sections were arranged so that their nozzles and outlets faced each other (see Figure 7). However, the configuration is not limited to this, and the upper and lower table sections may be arranged offset in a direction perpendicular to the longitudinal direction of the nozzles. For example, in the alternative configuration shown in Figure 8, the upper and lower table sections 11, 11 are arranged offset in the aforementioned perpendicular direction so that their nozzles 22a and outlets 23a do not face each other (in other words, they are offset by half a pitch). With this alternative configuration, the flow of hot air from the nozzle 22a to the outlet 23a can be offset in the aforementioned perpendicular direction by the upper and lower felt layers 52, 54, so that the laminated body to be heated 51 can be heated more uniformly in the planar direction. Note that this alternative configuration is the same as the above-described embodiment except for the arrangement of the upper and lower table sections 11, 11, so a detailed explanation is omitted.

[0034] In the embodiments described above, the heated laminate had a felt layer, but it is not limited to this, and other breathable layers can be applied instead of the felt layer. For example, a configuration in which a breathable layer made of a nonwoven fabric other than felt is laminated is also possible. Similarly, instead of a rubber-based sheet layer, a sheet layer made of a non-breathable sheet other than a rubber-based sheet, or a film layer made of a non-breathable film, can be applied as a non-breathable layer.

[0035] In the above-described embodiment, the laminate to be heated was configured with two felt layers of different weights on either side of a sheet layer. However, it is not limited to this configuration, and a configuration with felt layers of the same weight on either side of the sheet layer is also possible. Alternatively, the laminate to be heated may have a felt layer on only one side of the sheet layer. When heating this laminate to be heated, for example, hot air is passed through the felt layers as in the above-described embodiment, and hot air is applied directly or indirectly (e.g., with a thin plate in between) to the sheet layer. This allows the laminate to be heated to be heated.

[0036] In the embodiment described above, the system was configured with upper and lower hot air heating units, but it is not limited to this configuration, and a configuration with left and right hot air heating units can also be used. In this configuration as well, the laminate to be heated can be heated in the same way as in the embodiment described above by sandwiching the laminate to be heated between the support surfaces of the left and right hot air heating units, and the same effects can be achieved.

[0037] In the embodiment described above, the system was configured to heat a laminate to be heated, which consisted of a sheet layer sandwiched between felt layers, with two hot air heating units, one above the other. However, the system is not limited to this configuration, and it is also possible to have a hot air heating unit on only one side of the system. This configuration can be applied to heating a laminate to be heated, in which the felt layer is arranged on only one side of the sheet layer. That is, by blowing hot air onto the laminate to be heated while the felt layer is in contact with the support surface of the hot air heating unit, the felt layer and the sheet layer can be heated in the same way as in the embodiment described above. [Explanation of symbols]

[0038] 1. Hot air vent oven system 2. Hot air heating unit (hot air heating means) 15. Supply airspace (exhaust gas passage) 16. Emission airspace (emission gas passage) 21 Support surface part 22. Vent holes (vent gas passages) 22a spout 23. Discharge port (discharge gas passage) 23a Outlet 51 Heated laminate 52, 54 Felt layer (ventilation layer) 53. Sheet layer (non-ventilated layer)

Claims

1. A hot air ventilated oven apparatus that heats a flat plate-shaped laminate to be heated, in which a breathable layer and a non-breathable layer are laminated, and at least one of the outermost layers is made of the breathable layer, by blowing hot air onto the outermost breathable layer to allow air to circulate, The hot air heating means comprises a support surface portion that is in contact with the outer surface of the outermost ventilation layer, A hot air ventilated oven device characterized in that the support surface portion is provided with a plurality of outlets for ejecting the hot air toward the outermost ventilated layer and a plurality of outlets for discharging the hot air that has passed through the ventilated layer, all of which are arranged adjacent to each other.

2. The nozzle and the outlet each have a long slit shape. The hot air vent oven device according to claim 1, characterized in that the nozzle and the outlet are arranged alternately in a direction perpendicular to the longitudinal direction on the support surface.

3. The aforementioned hot air heating means is The hot air ventilated oven device according to claim 2, characterized in that it is equipped with an ejection gas passage connected to each nozzle and an exhaust gas passage connected to each outlet.

4. The system comprises two of the aforementioned hot air heating means, The hot air ventilated oven apparatus according to any one of claims 1 to 3, characterized in that both hot air heating means are arranged so that their support surfaces face each other.

Images