Assembly resin structure manufacturing apparatus

Abstract

To provide a knitted resin structure production device in which, even when the thickness of a molten resin aggregate is undefined, a contact area between the aggregate and both the sides of a lead-in part is large.SOLUTION: A knitted resin structure production device comprises: a feed part 10 feeding a molten resin; a linearization part 20 linearizing the molten resin fed from the feed part 10 by flowing out the same from a hole; a cooling tank 30 storing a cooling liquid cooling the linearized molten resin; and a lead-in part 50 arranged at the inside of the cooling tank 30 and rotating in a state of being contacted with the molten resin to successively pull the molten resin into the side of the bottom face of the cooling tank 30. The pull-in part 50 is made by separating a first rotor 51 and a second rotor 52 in a state where a rotational axis is made into a horizontal direction, and is variable from a state where the first rotor 51 and the second rotor 52 are parallel to a state where the first rotor 51 and the second rotor 52 are not parallel.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing a knitted resin structure that can be used for mattresses, cushioning materials, pillows, or daily necessities.

Background Art

[0002] A knitted resin structure having a three-dimensional network structure in which a large number of resins are entangled disorderly and partially heat-welded is used for mattresses and the like. The knitted resin structure can be obtained by cooling an aggregate of molten resin. For example, in Patent Document 1, when manufacturing a three-dimensional network structure by extruding molten thermoplastic resin downward from a plurality of nozzles, allowing it to naturally fall between a pair of belt conveyors partially submerged in water, and pulling it at a speed slower than the falling speed, the interval between the pair of belt conveyors is narrower than the width of the bundle of extruded molten resin, and both sides or one side of the bundle of molten resin comes into contact with the belt conveyor before the belt conveyor is submerged. A method for manufacturing a three-dimensional network structure is disclosed. Patent Document 2 discloses a network structure loop forming apparatus including opposing shoots, water supply portions for supplying water to the surfaces of the shoots respectively, and width setting plates provided oppositely so as to intersect the longitudinal direction of the shoots.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Disclosure of the Invention

Problems to be Solved by the Invention

[0004] As described in Patent Documents 1 and 2, the molten resin descends between a pair of drawing portions (such as a belt conveyor), and is drawn downward by the drawing portions. At this time, when manufacturing a knitted resin structure with a constant thickness like a mattress application, since the thickness of the molten resin aggregate is constant, it is easy to contact both sides of the drawing portions. However, when manufacturing a product with a variable thickness like a pillow application with a height difference, since the thickness of the molten resin aggregate is variable, there are portions that only contact one side of the drawing portion, and the surface molding may vary slightly depending on the location. Therefore, an object of the present invention is to provide a manufacturing apparatus for a knitted resin structure that can increase the contact area between the aggregate and both sides of the drawing portion even when the thickness of the molten resin aggregate is variable, such as when manufacturing a knitted resin structure for pillow applications where the thickness varies depending on the location.

Means for Solving the Problems

[0005] The manufacturing apparatus for a knitted resin structure of the present invention according to claim 1 includes a supply unit 10 for supplying molten resin, a linearizing unit 20 for making the molten resin supplied from the supply unit 10 linear by flowing it out from holes, a cooling tank 30 in which a cooling liquid for cooling the linear molten resin is stored, and a drawing unit 50 disposed in the cooling tank 30 and rotating in contact with the molten resin to draw the molten resin sequentially to the bottom side of the cooling tank 30. The drawing unit 50 is formed by separating a first rotating body 51 and a second rotating body 52 having a horizontal rotation axis, and is variable between a state where the first rotating body 51 and the second rotating body 52 are parallel and a state where the first rotating body 51 and the second rotating body 52 are not parallel. Either the first rotating body 51 or the second rotating body 52 has a fixed orientation, and only the other one can change its horizontal orientation. There are rotatable first rod members 81 and second rod members 83 provided in parallel with the first rotating body 51 and the second rotating body 52. A first rail member 91 having a screw groove and connected perpendicular to the first rod member 81 rotates with the rotation of the first rod member 81. A second rail member 92 having a screw groove and connected perpendicular to the second rod member 83 rotates with the rotation of the second rod member 83. One end of the first rotating body 51 or the second rotating body 52 with a fixed orientation is attached to the first rail member 91 without fitting into the screw groove, and one end of the first rotating body 51 or the second rotating body 52 whose orientation can be changed is fitted and attached to the screw groove. The other end of the first rotating body 51 or the second rotating body 52 with a fixed orientation is attached to the second rail member 92 without fitting into the screw groove, and the other end of the first rotating body 51 or the second rotating body 52 whose orientation can be changed is fitted and attached to the screw groove. One end of the first rotating body 51 or the second rotating body 52 fitted and attached to the screw groove moves along the first rail member 91 due to the rotation of the first rod member 81, and the other end of the first rotating body 51 or the second rotating body 52 fitted and attached to the screw groove moves along the second rail member 92 due to the rotation of the second rod member 83. It is characterized by the above. 。

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

[0007] Item 3 The present invention described in the claim is in claim 1Or in the manufacturing apparatus for a braided resin structure according to claim 2 characterized in that it comprises a coupling 100 for coupling the first rod member 81 and the second rod member 83.

Advantages of the Invention

[0008] According to the present invention, even when the thickness of the molten resin aggregate is indefinite, such as when manufacturing a braided resin structure for pillow use whose thickness varies depending on the location, a manufacturing apparatus for a braided resin structure capable of increasing the contact area between the aggregate and the drawing portion can be provided.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0010] The manufacturing apparatus for a braided resin structure according to the first embodiment of the present invention includes a supply unit for supplying molten resin, a linearizing unit for making the molten resin supplied from the supply unit flow out from holes to form a linear shape, a cooling tank in which a cooling liquid for cooling the linear molten resin is stored, and a drawing unit disposed in the cooling tank and rotating in contact with the molten resin to draw the molten resin sequentially to the bottom side of the cooling tank. The drawing unit is characterized in that a first rotating body and a second rotating body having a horizontal rotation axis are spaced apart, and are variable between a state where the first rotating body and the second rotating body are parallel and a state where the first rotating body and the second rotating body are not parallel. According to the present embodiment, it is possible to suppress the change in the speed at which the drawing portion draws the aggregate of molten resin depending on the location, and to eliminate the variation in the surface state of the braided resin structure formed by cooling the molten resin.

[0011] In the second embodiment of the present invention, in the apparatus for manufacturing a braided resin structure according to the first embodiment, either the first rotating body or the second rotating body has a fixed orientation, and only the other one can change its orientation in the horizontal direction. According to this embodiment, the apparatus configuration can be simplified compared to the case where both the first rotating body and the second rotating body can change their positions.

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

[0013] The fourth embodiment of the present invention is an apparatus for manufacturing a braided resin structure according to the third embodiment, in which one end and the other end of the first rotating body or the second rotating body with a changeable orientation are rotatable in the horizontal direction. According to this embodiment, when moving, one end or the other end of the first rotating body or the second rotating body automatically rotates to an appropriate angle, so that it can be moved smoothly.

[0014] The fifth embodiment of the present invention is a device for manufacturing a braided resin structure according to the third or fourth embodiment, which is provided with a coupling material for coupling a first rod member and a second rod member. According to this embodiment, when the first rod member and the second rod member are connected by a coupling, at least one of the first rotating body or the second rotating body can be translated to easily adjust the distance, and when the coupling is disconnected, the first rotating body or the second rotating body can be set at an oblique angle.

Example

[0015] Hereinafter, examples of the present invention will be described with reference to the drawings. FIG. 1 is a configuration diagram of a device for manufacturing a braided resin structure. The device for manufacturing a braided resin structure according to an example of the present invention continuously forms a braided resin structure 2 having a three-dimensional network structure in which a large number of resins are disorderly entangled and partially heat-welded by flowing down the molten resin linearly and immersing the aggregate 1 of the linear molten resin in a liquid such as water for cooling. The completed braided resin structure 2 is used as a mattress, a pillow, a cushion, or the like.

[0016] The device for manufacturing a braided resin structure includes a supply unit 10 for supplying molten resin, a linearizing unit 20 for making the molten resin linear, a cooling tank 30 in which a cooling liquid for cooling the linear molten resin is stored, a guide unit 40 through which the aggregate 1 of the linear molten resin flowing down from the linearizing unit 20 to the cooling tank 30 passes, a drawing unit 50 disposed in the cooling tank 30 and rotating in contact with the aggregate 1 of the molten resin to draw the aggregate 1 of the molten resin into the bottom surface side of the cooling tank 30 in order, and a sending unit 60 for sending the braided resin structure 2 out of the cooling tank 30.

[0017] The supply unit 10 melts and kneads a thermoplastic resin at a predetermined temperature to obtain a molten resin, and extrudes the molten resin at a predetermined extrusion rate to supply it to the linearizing unit 20. Examples of the thermoplastic resin include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polytetrafluoroethylene, acrylonitrile-butadiene-styrene resin, etc., which may be used alone or in combination of two or more.

[0018] The linearizing section 20 has an inlet at the upper part for receiving the molten resin extruded from the supply section 10, and an outlet at the bottom surface for discharging the received molten resin. A plurality of small holes are arranged at the outlet. The molten resin supplied from the supply section 10 becomes linear by flowing out from the small holes. The linear molten resin flowing out from each small hole forms an aggregate 1 and flows down toward the cooling tank 30.

[0019] A drawing-in section 50 and a delivery section 60 are arranged in the cooling tank 30. The drawing-in section 50 is arranged at a position where the aggregate 1 passing through the guide section 40 flows down into the cooling tank 30. The drawing-in section 50 has a pair of first rotators 51 and second rotators 52 provided facing each other. The first rotator 51 and the second rotator 52 are provided in parallel with a gap therebetween, and the aggregate 1 passes through the gap between the first rotator 51 and the second rotator 52. The aggregate 1 reaching the drawing-in section 50 is drawn into the bottom surface side of the cooling tank 30 in order while contacting at least one of the first rotator 51 and the second rotator 52. Each of the first rotator 51 and the second rotator 52 has two rotating rollers provided vertically and a belt bridged over the rotating rollers, and is configured such that the belt circulates like an endless track. Note that the first rotator 51 and the second rotator 52 can also be configured without a belt.

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

[0021] FIG. 2 is a top view of the drawing-in part 50. An attachment frame 70 is provided around the drawing-in part 50, and a rod member 80 is rotatably provided outside the attachment frame 70 in parallel with the first rotating body 51 and the second rotating body 52. Also, inside the attachment frame 70, a pair of rail members 90 are provided perpendicular to the rod member 80 with the drawing-in part 50 interposed therebetween. The rod member 80 is formed by connecting a first rod member 81 located on one end side of the drawing-in part 50 and a second rod member 83 located on the other end side of the drawing-in part 50 in series via a coupling 100. The first rod member 81 has a first handle 82 at its tip. The second rod member 83 has a second handle 84 at its tip.

[0022] The pair of rail members 90 consists of a first rail member 91 to which one end of the drawing-in part 50 is connected and a second rail member 92 to which the other end of the drawing-in part 50 is connected. One end of the first rail member 91 is connected to the attachment frame 70, and the other end is connected to the first rod member 81. A screw groove is formed in the first rail member 91. One end of the first rotating body 51 is attached to the first rail member 91 via a first attachment member 53 that does not fit into the screw groove, and one end of the second rotating body 52 is attached to the first rail member 91 via a second attachment member 54 that fits into the screw groove. Also, a swivel connection member is used for the connection between one end of the second rotating body 52 and the second attachment member 54, making one end side of the second rotating body 52 rotatable horizontally. One end of the second rail member 92 is connected to the attachment frame 70, and the other end is connected to the second rod member 83. A screw groove is formed in the second rail member 92. The other end of the first rotating body 51 is attached to the second rail member 92 via a first attachment member 53 that does not fit into the screw groove, and the other end of the second rotating body 52 is attached to the second rail member 92 via a second attachment member 54 that fits into the screw groove. Also, a swivel connection member is used for the connection between the other end of the second rotating body 52 and the second attachment member 54, making the other end side of the second rotating body 52 rotatable horizontally.

[0023] When the first handle 82 or the second handle 84 is rotated in a state where the first rod member 81 and the second rod member 83 are connected by the coupling 100, the entire rod member 80 rotates. Accordingly, the pair of rail members 90 also rotate, and the second rotating body 52 whose both ends are fitted in the screw grooves moves parallel along the rail member 90. On the other hand, the position of the first rotating body 51 whose both ends are not fitted in the screw grooves does not change. Thereby, as shown in FIGS. 2(a) and 2(b), the distance between the first rotating body 51 and the second rotating body 52 can be changed. Note that FIG. 2(a) shows a state where the distance between the first rotating body 51 and the second rotating body 52 is maximum, and FIG. 2(b) shows a state where the distance between the first rotating body 51 and the second rotating body 52 is minimum.

[0024] Also, when the first handle 82 is rotated with the coupling 100 disconnected, the first rod member 81 rotates. Accordingly, the first rail member 91 also rotates, and one end side of the second rotating body 52 fitted in the screw groove moves along the first rail member 91. On the other hand, the position of one end side of the first rotating body 51 not fitted in the screw groove does not change. Further, since the second rod member 83 does not rotate even when the first handle 82 is rotated, the position of the other end side of the second rotating body 52 does not change either. Thereby, as shown in FIG. 2(c), the second rotating body 52 becomes in an oblique state with respect to the first rotating body 51, and the distance between the first rotating body 51 and the second rotating body 52 can be made larger toward the other end side. Note that FIG. 2(c) shows a state where the distance between the first rotating body 51 and the second rotating body 52 at the other end side is maximum. Also, when the second handle 84 is rotated with the coupling 100 disconnected, the second rod member 83 rotates. Accordingly, the second rail member 92 also rotates, and the other end side of the second rotating body 52 fitted in the screw groove moves along the second rail member 92. On the other hand, the position of the other end side of the first rotating body 51 not fitted in the screw groove does not change. Further, since the first rod member 81 does not rotate even when the second handle 84 is rotated, the position of one end side of the second rotating body 52 also does not change. As a result, as shown in FIG. 2(d), the second rotating body 52 is in an inclined state with respect to the first rotating body 51, and the distance between the first rotating body 51 and the second rotating body 52 can be increased toward one end side. Note that FIG. 2(d) shows a state where the distance between the first rotating body 51 and the second rotating body 52 at one end side is maximized. Also, if the end of the second rotating body 52 is fixedly connected to the second attachment member 54, for example, when trying to move only one end side of the second rotating body 52, the other end side of the second rotating body 52 may move together, or the one end side of the second rotating body 52 may not move smoothly. However, in the present embodiment, since a swivel connection member is used for the connection between the end of the second rotating body 52 and the second attachment member 54, the end of the second rotating body 52 automatically rotates at an appropriate angle as it moves, thereby suppressing the movement of the other end side and enabling the one end side to move smoothly.

[0025] Thus, by providing the coupling 100 that couples the first rod member 81 and the second rod member 83 and rotating the first handle 82 or the second handle 84 with the first rod member 81 and the second rod member 83 connected by the coupling 100, the second rotating body 52 can be translated with respect to the first rotating body 51 to easily adjust the distance. Also, by rotating the first handle 82 or the second handle 84 with the coupling 100 disconnected, the second rotating body 52 can be inclined with respect to the first rotating body 51.

[0026] FIG. 3 is a diagram comparing the contact locations of the assembly 1 passing through the retraction portion 50. FIG. 3(a) shows a state where the first rotating body 51 and the second rotating body 52 are parallel, and FIG. 3(b) shows a state where the second rotating body 52 is inclined with respect to the first rotating body 51. When manufacturing the braided resin structure 2 used as a pillow with a height difference, the thickness of the aggregate 1 of the molten resin is not constant. Conventionally, the distance between the first rotating body 51 and the second rotating body 52 has been set according to the maximum thickness. However, since the first rotating body 51 and the second rotating body 52 are always parallel, as shown in Fig. 3(a), there are also portions that contact both surfaces of the aggregate 1, but there are also many portions that contact only one surface of the aggregate 1. Therefore, the speed at which the drawing portion 50 draws in the aggregate 1 varies slightly depending on the location, and the surface state of the braided resin structure 2 may change. On the other hand, in the braided resin structure manufacturing apparatus of the present embodiment, the first rotating body 51 and the second rotating body 52 can be in a parallel state and a non-parallel state, and the second rotating body 52 can be inclined with respect to the first rotating body 51. For this reason, as shown in Fig. 3(b), the portions that contact both surfaces of the aggregate 1 increase, and thereby, it is possible to suppress the speed at which the drawing portion 50 draws in the aggregate 1 from varying depending on the location, and eliminate the variation in the surface state of the braided resin structure 2.

[0027] Also, the braided resin structure manufacturing apparatus can be configured such that both the first rotating body 51 and the second rotating body 52 are movable. However, as in the present embodiment, by fixing the first rotating body 51 and making the second rotating body 52 movable, that is, by making one of the first rotating body 51 and the second rotating body 52 fixed and only the other one position-changeable, the apparatus configuration can be simplified.

Explanation of Signs

[0028] 1 Aggregate 2 Braided resin structure 10 Supply unit 20 Linearizing unit 30 Cooling tank 40 Guider unit 50 Drawing portion 51 First rotating body 52 Second rotating body 53 First attachment member 54 Second attachment member 60 Delivery unit 70 Attachment frame 80 Rod member 81 First rod member 82 First handle 83 Second rod member 84 Second handle 90 Rail material 100 Coupling 110 First rail material 120 Second rail material

Claims

1. A supply unit for supplying a molten resin; A linearizing unit that linearizes the molten resin supplied from the supply unit by allowing it to flow out through holes; A cooling tank in which a cooling liquid for cooling the linearized molten resin is stored; A drawing-in unit that is disposed in the cooling tank and rotates in contact with the molten resin to draw the molten resin sequentially to the bottom side of the cooling tank; and The drawing-in unit is formed by separating a first rotating body and a second rotating body having a horizontal rotation axis, and is variable between a state where the first rotating body and the second rotating body are parallel and a state where the first rotating body and the second rotating body are not parallel; Either the first rotating body or the second rotating body has a fixed orientation, and only the other one can change its horizontal orientation; Rotatable first rod member and second rod member provided in parallel with the first rotating body and the second rotating body; A first rail member having a screw groove and connected perpendicularly to the first rod member, and rotating with the rotation of the first rod member; A second rail member having a screw groove and connected perpendicularly to the second rod member, and rotating with the rotation of the second rod member; and One end of the first rotating body or the second rotating body with a fixed orientation is attached to the first rail member without fitting into the screw groove, and one end of the first rotating body or the second rotating body whose orientation can be changed is attached by fitting into the screw groove; The other end of the first rotating body or the second rotating body with a fixed orientation is attached to the second rail member without fitting into the screw groove, and the other end of the first rotating body or the second rotating body whose orientation can be changed is attached by fitting into the screw groove; One end of the first rotating body or the second rotating body attached by fitting into the screw groove moves along the first rail member by the rotation of the first rod member, and the other end of the first rotating body or the second rotating body attached by fitting into the screw groove moves along the second rail member by the rotation of the second rod member. A manufacturing apparatus for a braided resin structure, characterized in that.

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

3. The manufacturing apparatus for a braided resin structure according to claim 1 or claim 2, characterized in that it includes a coupling member that couples the first rod member and the second rod member.

Images