Method for manufacturing a molded body and apparatus for manufacturing a molded body

Abstract

To provide a method for manufacturing molded articles and a method for manufacturing molded articles using an apparatus that can easily produce high-quality molded articles. [Solution] A method for manufacturing a molded body comprising: a deposition step of depositing a fiber-containing material on a depositing member; a molding step of forming a first molded body by bonding the fibers of the deposited material together; and a bending step of generating a second molded body by bending the first molded body, wherein in the deposition step, a first portion and a second portion that is thinner than the first portion are generated in the deposited material, and in the bending step, the first molded body is bent at the second portion.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a molded article and an apparatus for manufacturing a molded article. [Background technology]

[0002] For example, Patent Document 1 discloses an apparatus for manufacturing a sheet from fibers. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2024-113315 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] However, sufficient consideration had not been given to manufacturing products using sheets produced by the method described in Patent Document 1. [Means for solving the problem]

[0005] A method for manufacturing a molded article according to an application example of the present invention comprises a deposition step of depositing a fiber-containing material onto a deposition member, A molding step in which the fibers of the aforementioned deposits are bonded together to form a first molded body, The process includes a bending step of bending the first molded body to produce a second molded body, In the aforementioned deposition process, a first portion and a second portion that is thinner than the first portion are generated in the sediment. In the bending process, the first molded body is bent at the second portion.

[0006] A molded body manufacturing apparatus according to an application example of the present invention has a deposit member on which a fiber-containing material is deposited, and a deposit section that generates a deposit of the said material, A molding section that forms a first molded body by bonding the fibers of the aforementioned deposit together, A bending part that bends the first molded body to generate a second molded body, and a control part that controls the operation of the deposition part. The control part controls the operation of the deposition part to generate the deposit having a first part and a second part thinner than the first part. The bending part generates the second molded body by bending at the second part.

Brief Description of Drawings

[0007] [Figure 1] FIG. 1 is a configuration diagram showing an outline of a molded body manufacturing apparatus according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a flowchart of a method for manufacturing a molded body according to a first embodiment of the present invention. [Figure 3] FIG. 3 is a block diagram of the molded body manufacturing apparatus shown in FIG. 1. [Figure 4] FIG. 4 is a cross-sectional view of a deposit generated by the deposition part shown in FIG. 1. [Figure 5] FIG. 5 is a cross-sectional view showing a deposition sheet, a laminate, and a first molded body. [Figure 6] FIG. 6 is a time chart for explaining the change over time in the thickness of the deposit and the moving speed of the deposit. [Figure 7] FIG. 7 is a cross-sectional view of a laminate generated by a molded body manufacturing apparatus according to a second embodiment of the present invention. [Figure 8] FIG. 8 is a cross-sectional view of a laminate generated by a molded body manufacturing apparatus according to a third embodiment of the present invention.

Modes for Carrying Out the Invention

[0008] Hereinafter, a method for manufacturing a molded body and a molded body manufacturing apparatus of the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.

[0009] <First Embodiment> Figure 1 is a schematic diagram showing the configuration of a molded body manufacturing apparatus according to the first embodiment of the present invention. Figure 2 is a flowchart of the method for manufacturing a molded body according to the first embodiment of the present invention. Figure 3 is a block diagram of the molded body manufacturing apparatus shown in Figure 1. Figure 4 is a cross-sectional view of the deposit generated by the deposit section shown in Figure 1. Figure 5 is a cross-sectional view showing the deposit sheet, the laminate, and the first molded body. Figure 6 is a time chart to explain the changes in the thickness of the deposit and the moving speed of the deposit over time.

[0010] In the following, the upper part of Figures 1, 4, and 5 (and similarly Figures 7 and 8) may be referred to as "up" or "above," and the lower part as "down" or "below." Also, Figure 1 is a schematic diagram, and the positional relationships, orientations, sizes, etc., of the various parts of the molded body manufacturing apparatus 100 are not limited to those shown. Furthermore, in Figure 1, the direction in which the material or molded body is conveyed is also referred to as the conveying direction.

[0011] [Molded object manufacturing equipment 100] The molded body manufacturing apparatus 100 shown in Figures 1 and 3 is an apparatus for carrying out the molded body manufacturing method of the present invention, and is an apparatus for molding a fiber-containing material M1 to produce a second molded body S4 as a molded body. The molded body manufacturing apparatus 100 comprises a deposition section 1, a cutting section 3, a molding section 4, a bending section 5, and a control device 7. Furthermore, as shown in Figure 2, the molded body manufacturing method comprises a deposition step, a cutting step, a molding step, and a bending step. In this embodiment, the case of manufacturing a book cover using the second molded body S4 is described, but the present invention is not limited thereto, and the final product manufactured by the second molded body S4 may be various things such as a mask, gloves, socks, handbag, business card case, slippers, etc. Also, the second molded body S4 may be the final product. The parts of the molded body manufacturing apparatus 100 and the steps of the molded body manufacturing method will be described in detail below.

[0012] (Material M1) First, let's describe material M1. Material M1 includes fibers F and a binder P that binds the fibers F together. Note that the binder P may be omitted.

[0013] Fiber F is not particularly limited and can include, for example, various natural fibers and various chemical fibers.

[0014] The average fiber length of fiber F is not particularly limited, but is preferably 0.1 mm to 10 mm, and more preferably 1 mm to 5 mm. This makes it possible to more reliably increase the strength of the second molded body S4 and to make processing such as the cutting and bending processes described later easier.

[0015] From a similar viewpoint, the average width (average diameter) of the fiber F is not particularly limited, but is preferably 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less.

[0016] From a similar viewpoint, the fiber F content in material M1 is not particularly limited, but is preferably, for example, 20% by weight or more and 99% by weight or less, and more preferably 50% by weight or more and 90% by weight or less.

[0017] Examples of binders P include thermoplastic resins such as various polyolefins, acrylic resins, polyvinyl chloride, polyester, and polyamide, various thermoplastic elastomers, and natural product-derived components such as starch, dextrin, glycogen, amylose, hyaluronic acid, kudzu, konjac, potato starch, etherified starch, esterified starch, natural gum glue, fiber-inducing glue, seaweed, and animal protein. One or more of these can be selected and used in combination.

[0018] The binder P is in the form of parts or fibers. When the binder P is in particulate form, its average particle size (by volume) is not particularly limited, but is preferably 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less. This makes it possible to more reliably increase the strength of the second molded body S4 and to make processing such as the cutting and bending processes described later easier.

[0019] From a similar viewpoint, when the binder P is fibrous, the average fiber length of the binder P is not particularly limited, but is preferably 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 10 mm or less.

[0020] From a similar viewpoint, when the binder P is fibrous, the average width (average diameter) of the binder P is not particularly limited, but is preferably 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less.

[0021] From a similar viewpoint, the content of the binder P in material M1 is not particularly limited, but is preferably, for example, 1% by weight or more and 80% by weight or less, and more preferably 10% by weight or more and 50% by weight or less.

[0022] Furthermore, material M1 may contain other components besides fiber F and binder P. Examples of such other components include colorants for coloring fiber F, flocculation inhibitors for suppressing the aggregation of fiber F, and flame retardants for making fiber F and the like less flammable. One or more of these can be used in combination. Also, if the fiber F itself dissolves or softens and bonds with other fiber F, then the binder P may not be included in addition to the fiber F.

[0023] If material M1 contains other components, the content of these other components in material M1 is not particularly limited, but is preferably, for example, 0.1% by weight or more and 10% by weight or less, and more preferably 0.5% by weight or more and 5% by weight or less. This allows for obtaining the effects of incorporating other components, while also ensuring sufficient amounts of fiber F and binder P, thereby more effectively increasing the strength of the second molded body S4.

[0024] (Deposition part 1, deposition process) As shown in Figure 1, the deposition section 1 is the part that performs a deposition process to generate a deposit M2 by depositing material M1 onto a mesh belt 12, which is a deposition member, while moving the mesh belt 12. As shown in Figure 1, the deposition section 1 includes a dispersion section 11, a mesh belt 12, a suction section 13, a sheet supply section 14, and a motor 82 as a moving section.

[0025] The dispersion unit 11 loosens and releases the intertwined fibers F in the material M1. The dispersion unit 11 includes a drum 111 for introducing and releasing the material M1, and a housing 112 for housing the drum 111.

[0026] The drum 111 is a sieve composed of a cylindrical mesh body that rotates around its central axis. As the drum 111 rotates, fibers F and other materials in the material M1 that are smaller than the mesh opening can pass through the drum 111. In this process, the material M1 is loosened and released along with the air. In other words, the drum 111 functions as a release unit that releases the material M1 containing the fibers F.

[0027] The drum 111 is connected to a motor 81, which acts as a drive source, and rotates due to the rotational force output from the motor 81. As shown in Figure 3, the motor 81 is electrically connected to a control device 7, and its operation is controlled.

[0028] Furthermore, the material M1 released from drum 111 disperses into the air as it falls, heading towards the mesh belt 12 located below drum 111.

[0029] A material supply unit (not shown) is connected to the drum 111. Examples of material supply units include those with a raw material supply unit, a crushing unit, a defibration unit, a mixing unit, etc., as described in Japanese Patent Publication No. 2024-113315, or those that supply material M1 in a cartridge type.

[0030] The mesh belt 12 is a deposit member, and in the illustrated configuration, it is composed of an endless belt. Sheets S are supplied to the mesh belt 12 from a sheet supply unit 14, which will be described later. Material M1 dispersed and released by the dispersion unit 11 is deposited on the sheets S, and deposits M2 are generated. The mesh belt 12 is wrapped around four tension rollers 121. The rotational drive of the tension rollers 121 transports the deposits M2 on the mesh belt 12 downstream.

[0031] In the illustrated configuration, an endless belt mesh belt 12 is used as an example of a deposit member. However, the present invention is not limited to this, and a configuration using a flat plate-shaped mesh member may also be used.

[0032] At least one of the four tension rollers 121 is connected to a motor 82 (moving part) which acts as a drive source, and rotates due to the rotational force output from the motor 82. The tension rollers 121 that are not connected to the motor 82 function as driven rollers. As shown in Figure 3, the motor 82 is electrically connected to a control device 7, and its operation is controlled.

[0033] The suction unit 13 is a suction mechanism that draws air from below the mesh belt 12. This allows the material M1 to be drawn onto the mesh belt 12. As a result, the accumulation of the material M1 onto the sheet S is promoted.

[0034] A pipe 131 is connected to the suction unit 13. A blower 132 is installed in the middle of this pipe 131. The operation of this blower 132 generates suction force in the suction unit 13. The blower 132 is electrically connected to the control device 7, and its operation is controlled by the control device 7.

[0035] The sheet supply unit 14 has a supply roller 141, and the function of dispensing the sheet S is achieved by the rotation of the supply roller 141. The sheet S dispensed by the supply roller 141 is supplied onto the mesh belt 12. Then, sediment M2 is generated on the sheet S. The sheet S and the sediment M2 accumulated on the sheet S together will be referred to as the "sediment sheet S1" below. However, if sediment M2 is formed on the mesh belt 12 without using the sheet S, or if the sheet S is removed after the sediment M2 has been formed, the sediment M2 alone may also be referred to as the sediment sheet S1.

[0036] The sheet supply unit 14 may be omitted. In this case, the material M1 is deposited directly onto the mesh belt 12.

[0037] The supply roller 141 is connected to the motor 83 and rotates due to the rotational force output from the motor 83. As shown in Figure 3, the motor 83 is electrically connected to the control device 7, and its operation is controlled.

[0038] The sheet S is breathable and is made of woven fabric, nonwoven fabric, etc. The fibers that make up the sheet S include those exemplified by the fiber F mentioned above. By supplying such a sheet S, the strength of the second molded body S4 can be more effectively increased, and processing such as the cutting process and bending process described later can be made easier.

[0039] As shown in Figure 5, the average thickness T of sheet S S While not particularly limited, the thickness is preferably 0.01 mm to 20 mm, and more preferably 0.1 mm to 2 mm. This makes it possible to more reliably increase the strength of the second molded body S4 and to make processing such as the cutting and bending processes described later easier.

[0040] From a similar perspective, the density ρ of material M1 in sediment M2 M1 This is not particularly limited, but is 0.01 g / cm³. 3 More than 2.0g / cm3 Preferably, it is 0.1 g / cm³ 3 More than 1.0g / cm 3 The following is more preferable.

[0041] From a similar perspective, as shown in Figure 5, the average thickness T of the sediment M2 M2 The average thickness of the first part 21 (described later) is not particularly limited, but is preferably 1 mm or more and 100 mm or less, and more preferably 1.5 mm or more and 50 mm or less.

[0042] From a similar perspective, the average thickness T of the deposited sheet S1 S1 The average thickness of the portion having the first portion 21 (described later) is not particularly limited, but is preferably 1.1 mm or more and 120 mm or less, and more preferably 1.3 mm or more and 60 mm or less.

[0043] (Cutting part 3, cutting process) As shown in Figure 1, the cutting unit 3 performs the cutting process and cuts the piled sheet S1 to a desired size. The cutting unit 3 has a pair of cutting blades 31 located downstream of the piled unit 1. Each cutting blade 31 is positioned vertically along the transport path of the piled sheet S1. Each cutting blade 31 is positioned so that its cutting edges face each other, and the cutting edges are configured to move closer together and further apart. When the cutting edges of each cutting blade 31 approach each other until they touch, the piled sheet S1 passing between them is cut. Furthermore, the length of the piled sheet S1 can be adjusted by adjusting the timing of the approach and separation of each cutting blade 31. Hereinafter, the piled sheet S1 cut to a predetermined length will be referred to as "piled sheet S2".

[0044] The cutting blade 31 is connected to a motor 84, which acts as a drive source, and moves closer to and further away from it by the force output from the motor 84. As shown in Figure 3, the motor 84 is electrically connected to a control device 7, and its operation is controlled.

[0045] Furthermore, a pair of transport rollers 32 are provided downstream of the cutting blade 31. They are positioned vertically along the transport path for the stacked sheet S2. The transport rollers 32 rotate while gripping the stacked sheet S2 after cutting, thereby transporting it downstream, i.e., to the molding section 4.

[0046] The transport roller 32 is connected to a drive source (not shown) and rotates due to the rotational force output from the drive source. The drive source is electrically connected to a control device 7, and its operation is controlled.

[0047] The cutting section 3 is not limited to the above configuration, and may have a cutting roller with blades formed on its outer circumference instead of the cutting blade 31.

[0048] Although not shown in the figures, the cutting section 3 may also have cutting blades that cut both edges in the width direction of the stacked sheet S1 or stacked sheet S2.

[0049] Furthermore, the cut section 3 may be omitted. In this case, it is preferable to fold the stacked sheets S1 and stack them in the thickness direction prior to performing molding in the molding section 4 described later.

[0050] (Molding section 4, molding process) As shown in Figure 1, the molding unit 4 has a pressurizing unit 41, and the process involves heating and pressurizing the deposited sheet S2 using the pressurizing unit 41 to compress the deposited sheet S2 and form the first molded body S3. In this embodiment, multiple deposited sheets S2 are stacked to form a laminate S21, and then the laminate S21 is heated and pressurized. That is, the deposited material M2 is stacked and each deposited material M2 is pressurized.

[0051] The number of deposited sheets S2 in the laminate S21 is not particularly limited, but is preferably between 1 and 20, and more preferably between 1 and 10. This allows for a more effective increase in the strength of the first molded body S3, which will be described later, and enables good bonding of adjacent laminated sheets S2.

[0052] In this embodiment, multiple sediment sheets S2 are stacked such that adjacent sediment sheets S2 in the thickness direction are in contact with one sheet S and the sediment M2 of the other. However, the configuration is not limited to this, and the sheets may be stacked so that one sheet S is in contact with the other sheet S, or so that one sediment M2 is in contact with the other sediment M2, or a stacking order may be a combination of such arrangements and the arrangement shown in the figure.

[0053] The pressurizing section 41 has block-shaped pressurizing members 411 and 412 as a pressurizing mechanism. The pressurizing members 411 and 412 are metal molds, but are not limited to metal molds; they may also be made of ceramics or the like. Multiple deposit sheets S2 are stacked and arranged on top of the pressurizing member 411. The pressurizing member 412 is connected to a drive source (not shown) and is configured to move closer to and further away from the pressurizing member 411. When the pressurizing member 412 approaches the pressurizing member 411, it sandwiches the deposit sheets S2 on the pressurizing member 411 between the pressurizing member 411 and the pressurizing member 412, and heats and pressurizes them to produce a first molded body S3. When the pressurizing is released, the deposit sheets S2 can be placed on the pressurizing member 411, or the first molded body S3 can be removed from the pressurizing member 411.

[0054] The pressurizing members 411 and 412 are not limited to a block shape, but may be composed of rollers, for example.

[0055] The above-mentioned drive source and heat source are electrically connected to the control device 7, and the pressurization timing, heating timing, degree of pressurization, and degree of heating are controlled. The pressurizing member 411 may also be connected to the heat source, or only the pressurizing member 411 may be connected to the heat source.

[0056] By applying pressure in the forming section 4, the fibers F in each deposited sheet S2 can be compressed to increase the density, and a first formed body S3 with relatively high strength can be formed. Also, adjacent deposited sheets S2 that are laminated can be joined more effectively. Further, by performing heating together with pressure in the forming section 4, the binder P in the deposited sheet S2 can be melted or softened and allowed to penetrate between the fibers F. Therefore, the fibers F can be joined to more effectively increase the strength of the first formed body S3, and adjacent deposited sheets S2 that are laminated can be joined well.

[0057] As shown in FIG. 5, the average thickness T of one deposited sheet S2 in the first formed body S3 S3 is not particularly limited, but is preferably 0.5 mm or more and 90 mm or less, and more preferably 1 mm or more and 40 mm or less. By applying pressure of this degree in the forming section 4, the strength of the first formed body S3 can be more effectively increased, and processing such as a bending process described later can be performed more easily.

[0058] The density ρ of the material M1 in one deposited sheet S2 of the first formed body S3 S3 (the density of the material M1 in the high-density portion 21A described later) is not particularly limited, but is preferably 0.03 g / cm 3 or more and 4.0 g / cm 3 or less, and more preferably 0.2 g / cm 3 or more and 2.5 g / cm 3 or less. By applying pressure of this degree in the forming section 4, the strength of the first formed body S3 can be more effectively increased.

[0059] The density ρ of the material M1 in the deposited sheet S2 S2 (g / cm 3 ) and the density ρ of the material M1 in one deposited sheet S2 of the first formed body S3 S3 (g / cm 3 ) and the ratio ρ S2 / ρ S3While not particularly limited, the pressure is preferably 0.2 to 0.8, and more preferably 0.3 to 0.7. By applying this level of pressure to the molding section 4, the strength of the first molded body S3 can be more effectively increased, and processing such as the bending process described later can be performed more easily.

[0060] The heating temperature in the molding section 4 is not particularly limited, but is preferably 40°C to 200°C, and more preferably 130°C to 190°C. This allows the binder P to be melted or softened more effectively, and the bonding between the fibers F to be strengthened. Thus, the strength of the first molded body S3 can be increased more effectively.

[0061] The time for which the molding section 4 is heated and pressurized is not particularly limited, but is preferably 1 second or more and 60 seconds or less, and more preferably 2 seconds or more and 45 seconds or less. This allows for more effective melting or softening of the binder P.

[0062] A cooling process may be performed after the molding process. The temperature after cooling should be such that the binder P solidifies, and is preferably room temperature. The cooling process is not particularly limited, but may involve contacting both sides of the first molded body S3 with a cooling block or cooling roller, blowing cold air onto the first molded body S3, or placing the first molded body S3 in a chamber to dissipate heat. Alternatively, the heating by the pressurizing members 411 and 412 may be released, and the pressurizing members 411 and 412 may be kept in contact with the first molded body S3 until their temperatures cool down.

[0063] By performing this cooling process, the binder P of the first molded body S3 can be solidified, thereby strengthening the bonds between the fibers F.

[0064] (Folding section 5, folding process) The bending section 5 is the part that performs the bending process to produce the second molded body S4 by bending the first molded body S3. Examples of the bending section 5 include a configuration in which the first molded body S3 is bent by rapidly changing the conveying direction while being conveyed by rollers, or a configuration in which the first molded body S3 is bent using a robot arm.

[0065] The lower limit of the bending angle in the bending process is preferably 1°, and more preferably 10°. The upper limit of the bending angle in the bending process is preferably 180°. This allows for a more effective enhancement of the product's value, for example, as a notebook cover.

[0066] The "bending angle" is a numerical value that indicates the degree to which the second molded body S4 is bent in its natural state without any external force applied, with the first molded body S3 in sheet form before bending set to 0°. For example, Figure 1 shows the state after bending at a bending angle of 180°.

[0067] By going through this bending process, a first molded body S3 having a bent portion, i.e., a second molded body S4, can be produced.

[0068] As will be described later, in the bending process, the bending process can be carried out easily and accurately by bending the portion of the first molded body S3 that corresponds to the second portion 22.

[0069] Furthermore, if necessary, cutting, sewing, printing, etc. may be performed before or after the folding process.

[0070] (Control device 7) Each component of the molded body manufacturing apparatus 100 is electrically connected to the control device 7. The operation of each component is controlled by the control device 7.

[0071] As shown in Figure 3, the control device 7 includes a control unit 71, a storage unit 72, and a communication unit 73.

[0072] The control unit 71 has at least one processor and executes various programs stored in the memory unit 72. For example, a CPU (Central Processing Unit) can be used as the processor. The control unit 71 also has various functions, such as controlling the drive of each part of the apparatus related to molded body manufacturing. Specifically, the control unit 71 controls the power supply conditions to motors 81 to 84, controls the supply speed of the sheet S, the movement speed of the mesh belt 12, and the rotational speed of the cutting timing in the cutting unit 3, and controls the thickness distribution of the deposit M2 as will be described later.

[0073] The memory unit 72 stores, for example, a program for executing the method for manufacturing the molded article of the present invention. The program for executing the method for manufacturing the molded article of the present invention may also be stored in a storage device other than the memory unit 72, such as the storage device of a server or an external storage device that can be attached to or removed from the control device 7.

[0074] The communication unit 73 is, for example, composed of an I / O interface and communicates with various parts of the molded body manufacturing apparatus 100. The communication unit 73 also has the function of communicating with a computer or server (not shown) via a network.

[0075] The control device 7 may be built into the molded body manufacturing apparatus 100, or it may be provided in an external device such as an external computer. Furthermore, the control unit 71 and the storage unit 72 may, for example, be integrated and configured as a single unit, or the control unit 71 may be built into the molded body manufacturing apparatus 100 and the storage unit 72 may be provided in an external device such as an external computer, or the storage unit 72 may be built into the molded body manufacturing apparatus 100 and the control unit 71 may be provided in an external device such as an external computer.

[0076] In the aforementioned deposition process, the moving speed of the mesh belt 12 is adjusted to form a portion in the deposition material M2 that will serve as the starting point for bending in the bending process. Specifically, in the deposition process, the moving speed of the mesh belt 12 is adjusted to form a first portion 21 and a second portion 22 that is thinner than the first portion 21 and will be bent in the bending process. This will be explained in detail below.

[0077] Note that the movement speed of the mesh belt 12 refers to the movement speed of the upper surface of the mesh belt 12, and is the same as the transport speed of the sediment M2.

[0078] In this embodiment, the first portion 21 and the second portion 22 are formed in the sediment M2 by synchronously adjusting the supply speed of the sheet S along with the movement speed of the mesh belt 12. Note that in a configuration where the sheet S is not supplied, the first portion 21 and the second portion 22 can be formed in the sediment M2 by adjusting only the movement speed of the mesh belt 12.

[0079] The control unit 71 reads and executes a program stored in the memory unit 72 to adjust the energization conditions of motors 82 and 83. This allows the rotational force output by motors 82 and 83 to be adjusted, thereby adjusting the moving speed of the mesh belt 12 and the supply speed of the sheet S.

[0080] When the movement speed of the mesh belt 12 and the supply speed of the sheet S are slowed down, the amount of material M1 deposited per unit area increases, resulting in a thicker deposit M2 and a higher basis weight of material M1. On the other hand, when the movement speed of the mesh belt 12 and the supply speed of the sheet S are increased, the amount of material M1 deposited per unit area decreases relatively, resulting in a thinner deposit M2 and a lower basis weight of material M1.

[0081] The control unit 71 adjusts the energizing conditions of motors 82 and 83 to generate a sediment M2 having a thickness distribution as shown in Figures 4 and 5. The sediment M2 has a first part 21 and a second part 22. Although the thickness of the sediment M2 actually changes, it is shown as having a uniform thickness in Figure 1 for convenience.

[0082] The first section 21 is a portion with a constant thickness and is the portion with the maximum thickness in the sediment M2. The average thickness of the first section 21 is the average thickness T mentioned above. S1 That is the case.

[0083] The second section 22 is thinner than the first section 21 and serves as the starting point for folding in the folding process. The second section 22 has a thinnest flat section 221, an inclined section 222 located upstream of the flat section 221 in the direction of movement of the mesh belt 12, and an inclined section 223 located downstream of the flat section 221 in the direction of movement of the mesh belt 12. These flat section 221, inclined section 222, and inclined section 223 extend across the entire depth direction in Figures 4 and 5, i.e., the width direction of the stacked sheet S2.

[0084] As shown in Figure 5, the average thickness T of the flat portion 221 221 While not particularly limited, it is preferably 0.01 mm to 15 mm, and more preferably 0.15 mm to 9 mm. This makes it possible to more reliably increase the strength of the first molded body S3 and to perform the bending process more easily and accurately.

[0085] Average thickness T of the flat section 221 221 (mm) and average thickness T of sediment M2 M2 (mm) Ratio T 221 / T M2 While not particularly limited, it is preferably 0.1 to 0.9, and more preferably 0.2 to 0.8. This makes it possible to more reliably increase the strength of the second molded body S4, and to perform the bending process more easily and accurately.

[0086] The thickest parts of the inclined sections 222 and 223 are the same thickness as the first section 21, and the thinnest parts are the same thickness as the flat section 221. In addition, the inclined sections 222 and 223 have the same angle of inclination, although they have different directions of inclination.

[0087] Length L of this second part 22 22 The length of the mesh belt 12 in the direction of movement is not particularly limited, but is preferably 5 mm or more and 50 mm or less, and more preferably 10 mm or more and 30 mm or less. This allows the bending angle to be increased more effectively and makes bending easier and more accurate.

[0088] Length L 22 (mm) and average thickness T 221 (mm) Ratio T 221 / L 22 While not particularly limited, the value is preferably 0.01 or more and 1.0 or less, and more preferably 0.1 or more and 0.5 or less. This allows the folding angle to be increased more effectively even when the thickness of the deposited sheet S2 is relatively thick, and also allows folding to be performed more easily and accurately.

[0089] The lengths of the flat section 221, the inclined section 222, and the inclined section 223 along the conveying direction are the same. However, the configuration is not limited to this, and they may be different. Also, the inclined sections 222 and 223 may have different inclination angles.

[0090] Such a second section 22 can be formed as follows. The deposition process will be explained below using the time chart shown in Figure 6.

[0091] Figure 6 illustrates the thickness of the sediment M2 (directly below the dispersion section 11) and the migration speed of the sediment M2, with the horizontal axis representing time and the vertical axis representing the velocity value. In Figure 6, the values ​​increase as you move upwards and decrease as you move downwards. The data is shown in chronological order from time t0 to time t7, but the amount of material M1 dispersed per unit time from the dispersion section 11 is assumed to be constant from time t0 to time t7 and thereafter.

[0092] The control unit 71 controls the operation of motors 82 and 83 so that the mesh belt 12 and the supply roller 141 operate at a moving speed V1 between time t0 and time t2. This ensures that the thickness of the deposit M2 generated between time t0 and time t2 remains constant. This part is the first part 21.

[0093] From time t2 to time t3, the control unit 71 controls the operation of motors 82 and 83 so that the speed continuously increases from the moving speed V1 to the moving speed V2 at time t3. As a result, the thickness of the deposit M2 generated between time t2 and time t3 gradually decreases. This section is the inclined section 222.

[0094] Between time t3 and time t4, the control unit 71 controls the operation of motors 82 and 83 so that the moving speed is V2. As a result, the thickness of the deposit M2 generated between time t3 and time t4 remains constant. This portion is the flat section 221.

[0095] From time t4 to time t5, the control unit 71 controls the operation of motors 82 and 83 so that the speed is continuously reduced from the moving speed V2 to the moving speed V1 at time t5. As a result, the thickness of the deposit M2 generated between time t4 and time t5 gradually increases. This section is the inclined section 223.

[0096] After time t5, the same control as that from time t0 to time t2 is repeated for a predetermined time. As a result, a deposited sheet S1 with the second part 22 formed at a predetermined interval can be obtained. By controlling the operation of the motor 84 so as to cut the deposited sheet S1 at a predetermined time interval, a deposited sheet S2 cut to a predetermined length can be obtained. Since the second part 22 is formed in this deposited sheet S2, the first molded body S3 has a uniform thickness, but the density of the material M1 in the part corresponding to the second part 22 is lower than that of the surroundings (the first part 21). That is, as shown in FIG. 5, in the first molded body S3, a high-density part 21A corresponding to the first part 21 and a low-density part 22A corresponding to the second part 22 are formed. In the bending process, the first molded body S3 can be easily and accurately bent starting from the low-density part 22A. As a result, a high-quality second molded body S4 can be easily obtained.

[0097] As described above, the method for manufacturing a molded body includes a depositing step of depositing a material M1 containing fibers F on a mesh belt 12 as a depositing member, a molding step of joining the fibers F of the deposit M2 to form a first molded body S3, and a bending step of bending the first molded body S3 to generate a second molded body S4. In the depositing step, a first part 21 and a second part 22 thinner than the first part 21 are generated in the deposit M2, and in the bending step, the first molded body S3 is bent at the second part 22. Thereby, in the bending step, the first molded body S3 can be easily and accurately bent starting from the part (low-density part 22A) corresponding to the second part 22. As a result, a high-quality second molded body S4 can be easily obtained.

[0098] In this embodiment, the moving speed V1 of the mesh belt 12 and the moving speed V2 of the mesh belt 12 satisfy V1 < V2, and by adjusting the moving speed of the mesh belt 12, the first part 21 and the second part 22 are formed in the deposit M2. However, in addition to this adjustment, the amount of dispersion of the material M1 in the dispersion part 11 may be further adjusted.

[0099] Furthermore, in the deposition process, the mesh belt 12 is moved at a speed V2 while the material M1 is deposited on the mesh belt 12 to form the second portion 22 of the deposited material M2, and the mesh belt 12 is moved at the aforementioned speed V1 while the material M1 is deposited on the mesh belt 12 to form the first portion 21 of the deposited material M2. This allows the second portion 22 to be formed with simple control.

[0100] Furthermore, during the deposition process, the movement speed of the mesh belt 12 is continuously varied between movement speed V1 and movement speed V2. Specifically, the control unit 71 controls the operation of motors 82 and 83 so that the speed is continuously increased from movement speed V1 from time t2 to time t3, reaching movement speed V2 at time t3, and then continuously decreased from movement speed V2 from time t4 to time t5, reaching movement speed V1 at time t5. This prevents abrupt changes in thickness between the first part 21 and the second part 22, and allows for increased strength at the boundary between the first part 21 and the second part 22.

[0101] Furthermore, the moving speeds V1 and V2 are set appropriately according to the desired thickness distribution of the first part 21 and the second part 22. The thickness distribution of the first part 21 and the second part 22 is set, for example, according to the bending angle in the bending process. That is, in the stacking process, the moving speed V2 is set according to the bending angle in the bending process. This makes it possible to obtain the desired bending angle in the bending process.

[0102] Furthermore, in the molding process, a laminate S21 is formed by stacking multiple deposition sheets S1 having a deposition M2 with a first portion 21 and a second portion 22, and then pressurizing the laminate to form the first molded body S3. This makes it possible to more effectively increase the strength of the first molded body S3. In particular, the portion of the first molded body S3 corresponding to the second portion 22 has a low density of material M1 and is relatively low in strength. For this reason, the above configuration is particularly effective.

[0103] The molded body manufacturing apparatus 100 has a mesh belt 12 as a deposition member on which material M1 containing fibers F is deposited, and comprises a deposition section 1 that generates a deposit M2 of material M1, a molding section 4 that forms a first molded body S3 by bonding the fibers F of the deposit M2 together, a bending section 5 that generates a second molded body S4 by bending the first molded body S3, and a control unit 71 that controls the operation of the deposition section 1. The control unit 71 controls the operation of the deposition section 1 to generate a deposit M2 having a first portion 21 and a second portion 22 that is thinner than the first portion 21, and the bending section 5 generates a second molded body S4 by bending at the second portion 22. As a result, in the bending process, the first molded body S3 can be easily and accurately bent starting from the portion corresponding to the second portion 22 (low-density portion 22A). As a result, a high-quality second molded body S4 can be easily obtained.

[0104] <Second Embodiment> Figure 7 is a cross-sectional view of a laminate produced by a molded body manufacturing apparatus according to the second embodiment of the present invention.

[0105] The following describes a second embodiment of the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention with reference to Figure 7, but only the differences from the above embodiment will be described.

[0106] As shown in Figure 7, in this embodiment, the laminate S21 has two deposition sheets S2. Hereinafter, the lower deposition sheet S2 will be referred to as "deposition sheet SA (first deposition)" and the upper deposition sheet S2 will be referred to as "deposition sheet SB (second deposition)". Furthermore, in the folding process, deposition sheet SA is folded to the outside and deposition sheet SB is folded to the inside.

[0107] As shown in Figure 7, the length L1 in the direction of movement of the mesh belt 12 of the second portion 22 in the deposition sheet SA is longer than the length L2 in the direction of movement of the mesh belt 12 of the second portion 22 in the deposition sheet SB. That is, in the deposition process, the movement speed of the mesh belt 12 is adjusted so that the length L1 in the direction of movement of the mesh belt 12 of the second portion 22 in the deposition sheet SA is longer than the length L2 in the direction of movement of the mesh belt 12 of the second portion 22 in the deposition sheet SB. By forming such a laminate S21, when comparing adjacent low-density portions 22A in the first molded body S3, the upper low-density portion 22A is shorter and the lower low-density portion 22A is longer.

[0108] In the bending process, when the first molded body S3 is bent so that the deposited sheet SB is located on the inside, the area of ​​bending or curving of the outer deposited sheet SA is longer than that of the inner deposited sheet SB. By taking this difference into consideration and making the length L1 of the second portion 22 in the deposited sheet SA longer than the length L2 of the second portion 22 in the deposited sheet SB, the low-density portion 22A described above is formed, and defects such as peeling and misalignment of the deposited sheets SA and SB due to bending or curving can be prevented or suppressed. Therefore, the quality of the second molded body S4 can be improved more effectively.

[0109] Thus, in any two of the deposition sheets S2 having the deposits M2 of the laminated body S21, when folded in the bending process, the deposition sheet S2 located on the outside is designated as the first deposition sheet SA, and the deposition sheet S2 located on the inside is designated as the second deposition sheet SB. In the deposition process, the moving speed of the mesh belt 12 is adjusted so that the length L1 in the transport direction of the mesh belt 12 of the second portion 22 of deposition sheet SA is longer than the length L2 in the transport direction of the mesh belt 12 of the second portion 22 of deposition sheet SB. This prevents or suppresses defects such as peeling and misalignment of deposition sheets SA and deposition sheet SB in the bending process. Therefore, the quality of the second molded body S4 can be improved more effectively.

[0110] In this embodiment, a configuration in which the laminate S21 has two deposition sheets S2 has been described, but the present invention is not limited to this, and a configuration having three or more deposition sheets S2 is also possible. In this case, if any two deposition sheets S2 satisfy the configuration of this embodiment, the above effects can be obtained.

[0111] The length L1 is not particularly limited, but is preferably 7 mm to 70 mm, and more preferably 15 mm to 45 mm. This allows for easier and more accurate bending while more effectively preventing or suppressing the above-mentioned problems.

[0112] The length L2 is not particularly limited, but is preferably 5 mm to 50 mm, and more preferably 10 mm to 35 mm. This allows for easier and more accurate bending while more effectively preventing or suppressing the above-mentioned problems.

[0113] The ratio L2 / L1, which is the ratio of length L1 (mm) to length L2 (mm), is not particularly limited, but is preferably between 0.1 and 0.9, and more preferably between 0.2 and 0.8. This allows for easier and more accurate bending while more effectively preventing or suppressing the above-mentioned problems.

[0114] <Third Embodiment> Figure 8 is a cross-sectional view of a laminate produced by a molded body manufacturing apparatus according to the third embodiment of the present invention.

[0115] The following describes a third embodiment of the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention with reference to Figure 8, but only the differences from the previous embodiment will be described.

[0116] As shown in Figure 8, the minimum thickness T1 of the second portion 22 in the laminated sheet SA is thicker than the minimum thickness T2 of the second portion 22 in the laminated sheet SB. That is, the average thickness of the flat portion 221 in the laminated sheet SA is thicker than the average thickness of the flat portion 221 in the laminated sheet SB. In this embodiment, although not shown in the figures, in the lamination process, the moving speed of the mesh belt 12 is adjusted so that the minimum thickness T1 of the second portion 22 in the laminated sheet SA is thicker than the minimum thickness T2 of the second portion 22 in the laminated sheet SB, thereby obtaining the laminated sheet SA and laminated sheet SB as described above. By forming such a laminate S21, when comparing adjacent low-density portions 22A in the first molded body S3, the density of material M1 is lower in the upper low-density portion 22A and higher in the lower low-density portion 22A.

[0117] In the folding process, when the laminated sheet SB is folded so that it is positioned on the inside, the outer laminated sheet SA experiences greater tension than the inner laminated sheet SB. As a result, the second portion 22 of the laminated sheet SA is more prone to breakage than the second portion 22 of the laminated sheet SB. Taking this into consideration, by setting the minimum thickness T1 of the second portion 22 in the laminated sheet SA to be thicker than the minimum thickness T2 of the second portion 22 in the laminated sheet SB, the low-density portion 22A described above is formed, and the breakage of the low-density portion 22A in the laminated sheet SA can be more effectively prevented or suppressed. Thus, the quality of the second molded body S4 can be more effectively improved, and the durability and yield of the second molded body S4 can be further enhanced.

[0118] Thus, in any two of the deposition sheets S2 having the deposits M2 of the laminated body S21, when folded in the bending process, the deposition sheet S2 located on the outside is designated as the first deposition sheet SA, and the deposition sheet S2 located on the inside is designated as the second deposition sheet SB. In the deposition process, the movement speed of the mesh belt 12 is adjusted so that the thickness T1 of the second portion 22 in deposition sheet SA is greater than the thickness T2 of the second portion 22 in deposition sheet SB. This makes it possible to more effectively prevent or suppress the breakage of deposition sheet SA in the bending process. Therefore, the quality of the second molded body S4 can be more effectively improved, and the durability and yield of the second molded body S4 can be further improved.

[0119] Density ρ of the low-density portion 22A of the deposited sheet SA in the first molded body S3 SA22 (g / cm 3 ) and the density ρ of the low-density portion 22A of the deposited sheet SB in the first molded body S3 SB22 (g / cm 3 ρ SB22 / ρ SA22 This is not particularly limited, but is preferably 0.2 to 0.8, and more preferably 0.3 to 0.7. This makes it possible to more effectively prevent or suppress the rupture of the low-density portion 22A in the deposited sheet SA. Thus, the quality of the second molded body S4 can be more effectively improved, and the durability and yield of the second molded body S4 can be further improved.

[0120] Although the present invention has been described in detail in the illustrated embodiments of the method for manufacturing a molded article and the molded article manufacturing apparatus, the present invention is not limited to these embodiments. Each part and each process constituting the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention can be replaced with any structure or process that can perform similar functions. Furthermore, any additional components or processes may be added to the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention. Moreover, the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention may be a combination of the features of each embodiment.

[0121] In particular, by combining the second and third embodiments, it is possible to prevent or suppress defects such as peeling and misalignment of the deposited sheets SA and SB during the bending process, and to more effectively prevent or suppress the rupture of the deposited sheet SA. Therefore, the quality, durability, and yield of the second molded body S4 can be more effectively improved.

[0122] Furthermore, although the above embodiments described a configuration in which the deposited sheets S2 are formed into a laminate S21 before molding, the present invention is not limited to this, and a configuration in which the deposited sheets S2 are formed first and then laminated together to form a laminate is also possible. In other words, the lamination process may be performed after the molding process.

[0123] Furthermore, the method of controlling the thickness of the deposited sheet S2 is not limited to controlling the thickness of the deposited sheet S2 by the movement speed of the mesh belt 12 and the supply speed of the sheet S. The thickness of the deposited sheet S2 may be controlled by other methods to create thicker and thinner areas in the deposited sheet S2. For example, the fiber-containing material M1 supplied to the dispersion section 11 may be supplied in larger quantities in areas where a thickness is desired and in smaller quantities in areas where a thinness is desired. Alternatively, after depositing the material on the deposited sheet S2 to a uniform thickness, the fibers in the areas where a thinness is desired may be removed from the deposited sheet S2. [Explanation of Symbols]

[0124] 1... Accumulation section, 3... Cutting section, 4... Molding section, 5... Bending section, 7... Control device, 11... Dispersion section, 12... Mesh belt, 13... Suction section, 14... Sheet supply section, 21... First section, 22... Second section, 31... Cutting blade, 32... Conveyor roller, 41... Pressurization section, 71... Control unit, 72... Memory section, 73... Communication section, 81... Motor, 82... Motor, 83... Motor, 84... Motor, 100... Molded body manufacturing device, 111... Drum, 112... Housing, 121... Tensioning roller, 131... Pipe, 132... Blower, 141... Supply roller, 221... Flat section, 222... Inclined section, 223... Inclined section, 411... Pressurizing member, 412... Pressurizing member, F... Fiber, M1... Material, M2... Accumulated material, L1... Length, L2... Length, L 22...length, P...bonding material, S...sheet, S1...laminated sheet, S2...laminated sheet, S21...laminated body, S3...first molded body, S4...second molded body, SA...laminated sheet, SB...laminated sheet, T1...minimum thickness, T2...minimum thickness, T 221 ...average thickness, T M2 ...average thickness, T S ...average thickness, T S1 ...average thickness, T S3 ...average thickness, V1...movement speed, V2...movement speed

Claims

1. A deposition process in which a fiber-containing material is deposited on a deposition member, A molding step in which the fibers of the sediment are bonded together to form a first molded body, The process includes a bending step of bending the first molded body to produce a second molded body, In the aforementioned deposition process, a first portion and a second portion that is thinner than the first portion are generated in the sediment. A method for manufacturing a molded article, characterized in that the first molded article is folded in the second portion during the bending process.

2. The moving speed V1 of the deposit member and the moving speed V2 of the deposit member satisfy V1 < V2. The method for manufacturing a molded body according to claim 1, wherein in the deposition step, the deposition member is moved at the moving speed V2 while the material is deposited on the deposition member to form the second portion of the deposition, and the deposition member is moved at the moving speed V1 while the material is deposited on the deposition member to form the first portion of the deposition.

3. The method for manufacturing a molded article according to claim 2, wherein in the deposition step, the moving speed of the deposition member is continuously changed between the moving speed V1 and the moving speed V2.

4. The method for manufacturing a molded article according to claim 2, wherein the transfer speed V2 is set in the deposition step according to the bending angle in the bending step.

5. The method for manufacturing a molded body according to claim 1 or 2, wherein in the molding step, a laminate formed by stacking a plurality of the deposits having the first portion and the second portion is pressed to form the first molded body.

6. In any two of the deposits of the laminated body, when folded in the folding process, the deposit located on the outside is designated as the first deposit, and the deposit located on the inside is designated as the second deposit. The method for manufacturing a molded body according to claim 5, wherein in the deposition step, the moving speed of the deposition member is adjusted so that the length in the direction of movement of the deposition member in the second portion of the first deposition is longer than the length in the direction of movement of the deposition member in the second portion of the second deposition.

7. In any two of the deposits of the laminated body, when folded in the folding process, the deposit located on the outside is designated as the first deposit, and the deposit located on the inside is designated as the second deposit. The method for manufacturing a molded body according to claim 5, wherein the moving speed of the deposition member is adjusted in the deposition step such that the thickness of the second portion in the first deposition is greater than the thickness of the second portion in the second deposition.

8. A deposit member having a material containing fibers that is deposited, and a deposit section that generates a deposit of the material, A molding section that forms a first molded body by bonding the fibers of the aforementioned deposit together, A bending portion which bends the first molded body to produce a second molded body, The system includes a control unit for controlling the operation of the accumulation section, The control unit controls the operation of the deposit section to generate the deposit having a first portion and a second portion that is thinner than the first portion. A molded body manufacturing apparatus characterized in that the bent portion generates the second molded body by bending the second portion.

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