Apparatus for manufacturing a functional mat, a method for manufacturing a functional mat, and a method for manufacturing an insole including a functional mat.

Abstract

To provide a functional mat manufacturing apparatus which can uniformly seal a porous body or can highly accurately change a content of a porous body as necessary, and a manufacturing method of the same.SOLUTION: A manufacturing apparatus Z for manufacturing a functional mat X sandwiching a granular porous body 2 in an overlapped part of two or more sheet materials 1 includes: a feeding device 3 for moving the sheet materials 1 in a predetermined direction and making the sheet materials sandwich the porous body 2; a spraying device 4 for spraying the porous body 2 onto one surface of the sheet material 1; and an entangling device 5 for entangling and connecting the sheet materials 1 sandwiching the porous body 2, in which the spraying device 4 has an adjustment part P capable of adjusting the spray amount of the porous body 2.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a manufacturing apparatus capable of manufacturing a functional mat that is used for materials constituting interior decorations of buildings, household goods, etc., and has excellent functions such as hygroscopicity and deodorization.

Background Art

[0002] There are various situations where moisture absorption and deodorization are required, such as ventilation inside buildings, prevention of mold in bedding, and prevention of stuffiness in shoes. In this regard, porous materials such as activated carbon and silica gel are used, and in order to apply these in various forms such as wall surfaces and filters, a configuration in which they are sandwiched between highly breathable sheet materials is used. Here, since the porous material cannot perform functions such as moisture absorption and deodorization unless it comes into contact with air, it was necessary to devise a way to appropriately expose the porous material to air between the sheet materials while at the same time preventing it from spilling outside the sheet materials.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The functional mat described in Patent Document 1 has a configuration in which silica gel is sprayed and sandwiched between two mat bodies, and the fibers of the non-woven fabrics are entangled by needle punching to hold the internal silica gel. However, it is preferable that such a functional mat can be flexibly changed, such as spraying silica gel uniformly or changing the spraying amount of silica gel as needed.

[0005] In view of the above problems, an object of the present invention is to provide a manufacturing apparatus for a functional mat that can uniformly enclose a porous body or can change the content of the porous body with high precision as needed, and a manufacturing method thereof.

Means for Solving the Problems

[0006] The present invention, which solves the above problems, is a manufacturing apparatus for producing a functional mat in which a granular porous body is sandwiched between two or more sheet materials in an overlapping portion, comprising: a feeding device that moves the sheet materials in a predetermined direction and sandwiches the porous body; a dispensing device that scatters the porous body on one surface of the sheet materials; and an entanglement device that intertwines and connects the sheet materials sandwiching the porous body, wherein the dispensing device has an adjustment unit that can adjust the amount of the porous body that is scattered. This configuration allows for the uniform encapsulation of porous materials in the manufacturing of functional mats, or enables precise adjustment of the silica gel content as needed.

[0007] In a preferred embodiment of the present invention, the spraying device has a hopper, and the adjustment unit is provided with a spraying amount adjustment member at the discharge port of the hopper. This configuration allows for easy adjustment of the amount of porous material sprayed per unit time.

[0008] In a preferred embodiment of the present invention, the dispensing amount adjusting member is a rotating body that can rotate about one pivot axis, and has a retaining portion on its outer circumferential surface that can hold the granules of the porous material. This configuration allows for easy adjustment of the amount of porous material to be sprayed while limiting its particle size.

[0009] In a preferred embodiment of the present invention, the adjustment unit is further provided with a position-adjustable measuring member in the gap between the discharge port and the spray volume adjustment member. This configuration allows for more uniform distribution of the porous material.

[0010] In a preferred embodiment of the present invention, the invention further comprises a heating section capable of heat-treating the functional mat. This configuration allows for easy modification of the properties of the functional mat.

[0011] The present invention, which solves the above problems, is a manufacturing method for producing a functional mat in which a granular porous body is sandwiched between two or more sheet materials in an overlapping portion, comprising: a spraying step of spraying the porous body onto one surface of the sheet materials; a feeding step of moving the sheet materials in a predetermined direction and sandwiching the porous body between them; and an entanglement step of intertwining and connecting the sheet materials that sandwich the porous body, wherein the spraying step further includes a spraying amount adjustment step in which the amount of the porous body sprayed can be adjusted by a spraying device having an adjustment unit. This manufacturing method allows for the uniform encapsulation of porous materials in the production of functional mats, or enables precise adjustment of the silica gel content as needed.

[0012] The present invention, which solves the above problems, is a manufacturing method for producing an insole including a functional mat in which a granular porous material is sandwiched between two or more sheet materials, comprising: a scattering step of scattering the porous material onto one surface of the sheet materials; a feeding step of moving the sheet materials in a predetermined direction and sandwiching the porous material between them; an entanglement step of intertwining and connecting the sheet materials that sandwich the porous material between them; a cutting step of cutting the functional mat into a predetermined shape; and a sewing step of sewing the peripheral edges of the cut functional mat together, wherein the scattering step further includes a scattering amount adjustment step in which the amount of the porous material scattered can be adjusted by a scattering device having an adjustment unit. This manufacturing method makes it possible to produce insoles in which porous materials can be uniformly encapsulated, or in which the silica gel content can be changed with high precision as needed. [Effects of the Invention]

[0013] To solve the above problems, the present invention provides a manufacturing apparatus for a functional mat that can uniformly encapsulate a porous material, or change the content of the porous material with high precision as needed, and a method for manufacturing the same. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic diagram showing the configuration of a functional mat according to the first embodiment of the present invention. [Figure 2]It is a schematic diagram showing the configuration of a manufacturing apparatus for a functional mat according to the first embodiment of the present invention. [Figure 3] It is a schematic diagram showing the configuration of a spraying device in a manufacturing apparatus for a functional mat according to the first embodiment of the present invention. [Figure 4] It is a schematic diagram showing the configuration of a functional mat and its manufacturing apparatus according to the second embodiment of the present invention. [Figure 5] It is a schematic diagram showing the configuration of a manufacturing apparatus for a functional mat according to the third embodiment of the present invention. [Figure 6] It is a schematic diagram showing the configuration of a functional mat according to the third embodiment of the present invention.

Embodiments for Carrying Out the Invention

[0015] Hereinafter, with reference to the drawings, the functional mat X and the manufacturing apparatus Z according to each embodiment of the present invention will be described. The description will detail the configuration of the embodiment, the method of implementation, and other examples in this order. Note that each of the embodiments shown below is an example of the present invention, and the present invention is not limited to the following embodiments.

[0016] ≪First Embodiment≫ As shown in FIGS. 1(a) and 1(b), the functional mat X according to this embodiment has a configuration in which granular porous bodies 2 are sandwiched between overlapping portions (superposed portions; the same applies hereinafter) of at least two (two or more) sheet materials 1. Thereby, the porous bodies 2 perform moisture absorption and deodorization inside the functional mat X.

[0017] The sheet material 1 is a member having air permeability and being easily deformable, and is preferably an aggregate of fibers such as non-woven fabric, cotton, and spunlace. With such a configuration, a space for introducing air into the sandwiched porous bodies 2 can be secured, and the hygroscopicity and deodorizing properties of the porous bodies 2 can be fully utilized.

[0018] The porous body 2 is a granular material having a large number of irregularities on its surface, and by storing and holding gas, moisture, etc. in the recesses, it enables moisture absorption and deodorization of the surroundings. The material of the porous body 2 is not particularly limited as long as it has moisture absorption and deodorization properties. However, from the perspective of being granular with a certain particle size as in this embodiment, silica gel, pumice, etc. are preferable.

[0019] As shown in Fig. 1(b), in the layer where the porous body 2 is sandwiched by the sheet material 1, cross-linked fibers 11 extend from the sheet material 1. The cross-linked fibers 11 are formed by pulling out the fibers contained in the sheet material 1, and by being wound around the sheet material 1 on the opposite side of the layer of the porous body 2, they cross-link between the two sheet materials 1 to hold the porous body 2 that does not have a holding means such as the shape of the functional mat X and an adhesive. With such a configuration, a gap is secured around the granules of the porous body 2 to hold the shape of the functional mat X, and the moisture absorption and deodorization properties of the porous body 2 can be utilized.

[0020] Fig. 1(c) shows an insole Y cut out in the shape of a shoe sole from the functional mat X. The insole Y is obtained by cutting out the functional mat X shown in Fig. 1(a) and Fig. 1(b) into a predetermined shape (such as the shape of a shoe sole, the shape of the sole of the foot, etc.), and at the peripheral edge, sewing the two sheet materials 1 together to form a bag shape. With such a configuration, high moisture absorption and deodorization can be ensured inside the shoe, and the usability can be improved.

[0021] The insole Y may be provided with an additional resin layer formed by thermoforming a thermosetting resin or the like on one of the sheet materials 1 of the functional mat X, and may be a cup insole with the peripheral edge of the other sheet material 1 rising up. With such a configuration, the insole Y can stably contact the user's foot, and the usability can be improved. Further, the insole Y may be further laminated with a layer having shock absorption properties (such as a mesh fabric), a layer that can improve strength (such as a knitted fabric), a slip prevention layer (such as a rubber sheet), a heat retention layer (such as a boa fabric), etc.

[0022] As shown in Figure 2(a), the manufacturing apparatus Z is capable of producing the aforementioned functional mat X and comprises a feeding device 3, a dispensing device 4, and an entanglement device 5. The dispensing device 4 also has an adjustment unit P that can adjust the amount of porous material 2 dispensed per unit time (hereinafter simply referred to as "dispensing amount"). This allows the amount of porous material 2 contained in the functional mat X to be adjusted as needed.

[0023] The feeding device 3 feeds the strip-shaped sheet material 1 in the length direction at a predetermined speed, forming the production line of the manufacturing device Z. The feeding device 3 also has, in order from upstream, a dispensing roller 31, a clamping roller 32, and a winding roller 33, and may further have a turning roller 34 if necessary.

[0024] The feed roller 31 is a columnar or tubular member located at the uppermost part of the feed-out process for the sheet material 1, and has a pivot axis in a direction that is horizontal and perpendicular to the direction in which the sheet material 1 is fed (hereinafter referred to as the width direction). As a result, the feed roller 31 rotates, and the sheet material 1 wrapped around its side (around the pivot axis) is pulled out and sent to the downstream process.

[0025] The clamping rollers 32 are a pair of rollers that sandwich the porous material 2 scattered between two or more sheet materials 1 sent from the feed rollers 31. Each of the rollers constituting the clamping rollers 32 has a pivot axis in the width direction and is a cylindrical or tubular member. Furthermore, it is preferable that the gap between the pair of clamping rollers 32 be adjustable as needed. This configuration allows the thickness of the functional mat X to be changed according to the thickness of the sheet materials 1 and the amount of porous material 2.

[0026] The winding roller 33 is a columnar or tubular member located at the downstream end of the manufacturing apparatus Z, and has a pivot axis in the width direction. This causes the winding roller 33 to rotate, and the functional mat X is wound around its side (around the pivot axis) and collected.

[0027] The direction-changing roller 34 is a roller used to change and adjust the direction in which the sheet material 1 or functional mat X is fed, and is a cylindrical or tubular member having a pivot axis in the width direction. In this embodiment, by appropriately providing the direction-changing roller 34, it is possible to secure space for other devices between the paths for feeding the two sheets of sheet material 1, or to keep the overall size of the manufacturing apparatus Z down. For example, in Figure 2(a), a directional roller 34 is provided on the path for the upper sheet material 1 in order to secure space for a spreading device 4 between the paths for sending the two sheet materials 1.

[0028] The spreading device 4 is a device capable of spreading the porous material 2 onto the surface of the sheet material 1 that is fed by the feeding device 3, and includes a hopper 41, a spreading amount adjustment member 42, and a basis member 43. Furthermore, the aforementioned adjustment unit P is a collective name for the spreading amount adjustment member 42 and the basis member 43.

[0029] The hopper 41 is a tank capable of storing and discharging a fixed amount of granular material, and has a storage section 411 and a discharge port 412. Preferably, the width of the hopper 41 is approximately the same as the width of the sheet material 1 or each roller in the direction in which the sheet material 1 is fed. With this configuration, granules of the porous material 2 can be scattered from a single dispensing device 4.

[0030] The storage section 411 is a tank capable of storing a predetermined amount of granular material, and is a box-shaped member having the same width as the hopper 41. The discharge port 412 is a hole provided at the bottom of the storage section 411, and discharges the material stored in the storage section 411, such as granules of porous material 2, downwards. The discharge port 412 has approximately the same width as the storage section 411, and its length in the direction in which the sheet material 1 is fed is determined in correspondence with the adjustment section P, which will be described later. Furthermore, it is preferable that the bottom surface of the storage section 411 is sloped downwards toward the discharge port 412. With such a configuration, the material inside the storage section 411 flows more reliably toward the discharge port 412, and uneven dispensing can be suppressed.

[0031] The spray volume adjustment member 42 is a cylindrical or tubular member provided to block a portion of the discharge port 412, and is a rotating body having a pivot axis in one direction. In this embodiment, as shown in Figure 3(a), it has a pivot axis in the width direction, and the central axis of the cylindrical or tubular member and the pivot axis are the same, and it rotates to sweep the discharge port 412.

[0032] The dispensing amount adjustment member 42 has numerous holding portions 421 on its outer circumferential surface. The holding portions 421 are recesses or holes provided on the outer circumferential surface of the dispensing amount adjustment member 42 that face inward when rotated, and they hold the granules of the porous body 2. As a result, as shown in Figure 3(c), the granules of the porous body 2 are held in the holding portions 421 and are removed from the hopper 41 in accordance with the rotation of the dispensing amount adjustment member 42. Subsequently, when the opening of the holding portion 421 faces vertically downward due to rotation, the porous body 2 falls from the holding portion 421 and is dispersed onto the sheet material 1.

[0033] Preferably, the gap between the dispensing amount adjustment member 42 and the discharge port 412 of the hopper 41 is approximately equal to the diameter of the granules of the porous material 2 in the holding portion 421, or the gap is slightly larger. With this configuration, only the granules of the porous material 2 in the hopper 41 that enter the holding portion 421 are dispensed onto the sheet material 1, so the dispensing amount can be easily adjusted by the angular velocity at which the dispensing amount adjustment member 42 rotates.

[0034] The measuring member 43 is a member provided near the gap between the spraying amount adjustment member 42 and the discharge port 412, and adjusts the amount of porous material 2 sprayed. As shown in Figure 3(c), the measuring member 43 translates in a direction that expands or contracts the gap between the spraying amount adjustment member 42 and the discharge port 412, and adjusts the amount of porous material granules discharged from the gap at one time. With this configuration, the spraying amount can be easily adjusted even when the gap is wider than the particle size of the porous material granules, or when a spraying amount exceeding the angular velocity adjustment range of the spraying amount adjustment member 42 is required. The shape of the spreading member 43 is not particularly limited as long as it allows for adjustment of the amount of porous material 2 sprayed, or changes in the gap between the discharge port 412 and the spraying amount adjustment member 42. However, a shape that corresponds to the actual handling and the shape of the discharge port 412 is preferred, and examples include a flat plate shape, a columnar shape, a wedge shape, etc.

[0035] The entanglement device 5 comprises a drive device 51 and a needle 52, and is a device for entangling and connecting multiple sheet materials 1 that hold granules of the porous body 2. Needle punching is used to connect the sheet materials 1, and the drive device 51 swings the needle 52 up and down to the extent that the needle 52 penetrates all of the sheet materials 1.

[0036] As shown in Figure 2(b), the needle 52 has a needle body portion 521 and a protruding portion 522 that protrudes from the side of the needle body portion 521. By penetrating the sheet material 1 and then pulling it back, it loosens and extracts the fibers contained in the sheet material 1. As a result, the fibers of multiple sheet materials 1 crosslink with each other across the layer of porous body 2, connecting the sheet materials 1 together. In addition, the crosslinking fibers 11 that connect the sheet materials 1 surround the granules of the porous body 2, making them able to be held between the sheet materials 1.

[0037] In Figures 2(a) and 2(b), only one needle 52 is shown for illustrative purposes, but it is preferable to have multiple needles 52 in a single entanglement device 5. More preferably, a predetermined number of needles (e.g., m rows and n columns) are provided in the feed direction and width direction, according to the width and feed speed of the sheet material 1. With such a configuration, the sheet materials 1 can be connected to each other efficiently and firmly, and the granules of the porous body 2 can be held stably.

[0038] In the system for operating the manufacturing apparatus Z of this embodiment, the operating state of the feeding device 3 (which may be either the angular velocity at which any of the rollers rotate, or the speed at which the sheet material 1 is fed) and the operating state (angular velocity) of the spreading amount adjustment member 42 may be individually controllable, or they may be linked and depend on one of the other. Preferably, both can be switched. With such a configuration, the amount of porous material 2 contained in the functional mat X can be easily changed.

[0039] The manufacturing apparatus Z may have the following configurations. However, the configurations shown below are merely examples, and their presence or absence can be determined arbitrarily unless otherwise specified.

[0040] <Example of changes> The feed roller 31 may be a mounting part (such as a bearing or a support base supported by rollers) on which a columnar member having a pivot axis in the width direction can be rotatably installed, instead of the configuration shown in Figure 2(a). In this case, the sheet material 1 wound around the pivot axis is supported by the feed roller 31, and the sheet material 1 is fed by rotating the winding roller 33 to pull it out in the direction of the winding roller 33. With this configuration, the process of installing the sheet material 1 in the manufacturing apparatus Z can be simplified, and the work related to the manufacturing of the functional mat X can be made more efficient.

[0041] The clamping rollers 32 may be configured to allow for adjustment of the distance between the pair of rollers. For example, the upper roller may be configured to move up and down in the vertical direction. Such a configuration allows the functional mat X passing between the two rollers to be adjusted to a desired thickness.

[0042] As shown in Figures 2 and 3, the spraying device 4 may have a slope 44. The slope 44 is a flat plate-shaped member that extends from near the outer surface of the spraying amount adjustment member 42 to near the height of the sheet material 1 on which the porous material 2 is sprayed. It is sloped downwards toward the sheet material 1, and the granules of the porous material 2 slide down on it. This reduces the length over which the porous material 2 free-falls from the holding part 421 to the sheet material 1, making it less likely for the landing point of the sheet material 1 to vary, and allowing the porous material 2 to be sprayed onto the sheet material 1 more uniformly.

[0043] The following describes in detail the method of carrying out the present invention with reference to the drawings. Furthermore, the method of carrying out the invention described below is merely an example, and is not limited to this method; the order of the steps may also be changed.

[0044] ≪Implementation Method≫ The user first attaches the sheet material 1 to the feeding device 3. At this time, the sheet material 1 is wrapped around the feed roller 31, passed between the clamping rollers 32, and then the leading edge of the sheet material 1 is wound up by the winding roller 33. Furthermore, by attaching auxiliary cloths with a length from the feed roller 31 to the winding roller 33 to both ends in the direction in which the sheet material 1 is fed, the porous material 2 can be automatically sprayed over the entire sheet material 1, thereby improving production efficiency.

[0045] Next, the user places the granular porous material 2 into the hopper 41 and determines the angular velocity of the spreading amount adjustment member 42 and the position of the basis marking member 43 (spreading amount adjustment step). Then, the feeding device 3 is operated to move the sheet material 1 in the direction of the winding roller 33 (feeding step), and the spreading amount adjustment member 42 is rotated accordingly to spread the porous material 2 onto the surface of the sheet material 1 (spreading step). At this time, the operating states of the feeding device 3 and the spreading amount adjustment member 42 may be controlled individually, or they may be linked and depend on one of the other.

[0046] After multiple sheet materials 1 have sandwiched the granules of the porous body 2, or in conjunction with the start of operation of the feeding device 3, the user operates the entanglement device 5 to entangle and connect the fibers of the multiple sheet materials 1 (entanglement process). This generates cross-linked fibers 11, and the granules of the porous body 2 are held between the layers of the sheet materials 1.

[0047] The user then removes the functional mat X wound onto the winding roller 33, cuts the functional mat X into a strip or any other shape, or cuts it out using a die (cutting process), and sews the edges together to connect the sheet materials 1 (suturing process). This prevents the granules of the porous material 2 sealed inside the functional mat X from leaking out. First, the strip-shaped functional mat X can be applied to bedding (futons, mattresses, etc.) and other items that require a certain size. In addition, the cut shapes can be, for example, circular or shoe sole shapes. The former can be applied to filters for piping and ventilation devices, and the latter to insoles Y shown in Figure 1(c). In particular, when layering or attaching another fabric to the functional mat X, it is preferable to attach all the fabrics before the cutting process.

[0048] In addition to the above, Functional Mat X can be used as a moisture absorber and deodorizer in factories, logistics facilities (warehouses, containers, etc.), homes (closets, shoe cabinets, entrances, toilets, etc.), nursing care facilities, medical facilities, etc. However, these are merely examples, and Functional Mat X may be used in other environments as well.

[0049] Hereinafter, a functional mat X and a manufacturing apparatus Z according to a second embodiment of the present invention will be described with reference to the drawings. Note that components similar to those in the first embodiment will be described using the same reference numerals, and their explanation will be omitted.

[0050] ≪Second Embodiment≫ As shown in Figure 4(a), the feeding device 3 has three feeding rollers 31. This differs from the first embodiment in that another sheet material 1 is added to the underside of the sheet material 1 on which the porous material granules 2 are scattered, and as shown in Figure 4(b), a functional mat X is manufactured in which two layers of sheet material 1 are provided on only one side.

[0051] As shown in Figure 4(b), the functional mat X has a porous body 2 sandwiched between two sheet materials 1, with another sheet material 1 laminated on one side. This third sheet material 1 has a pattern printed on it, which allows for a patterned functional mat X.

[0052] As shown in Figure 4(a), the clamping roller 32 clamps the granules of the porous material 2 between the layers of two sheet materials 1, while simultaneously laminating a third sheet material 1. This makes it possible to laminate three or more sheet materials 1 while keeping the number of parts to a minimum. Furthermore, by using a manufacturing apparatus Z and manufacturing method that laminates sheet materials 1 with pre-printed patterns, it becomes easier and more efficient to print on a thin and simple object compared to printing patterns on a functional mat X after it has been completed, as it is possible to print on the object.

[0053] The entanglement device 5 swings the needle 52 up and down so that it penetrates the three sheet materials 1 at once, and connects the fibers of each sheet material 1 by needle punching. This ensures that each sheet material 1 is stably connected to the others.

[0054] The functional mat X and manufacturing apparatus Z according to the third embodiment of the present invention will be described below with reference to the drawings. Note that components similar to those in the first and second embodiments will be described using the same reference numerals.

[0055] ≪Third Embodiment≫ As shown in Figures 5(a) and 5(b), the manufacturing apparatus Z includes a heating unit 6 downstream of the entanglement device 5, which is capable of heat-treating the functional mat X. The heating unit 6 is a device capable of heating the sheet material 1 to a predetermined temperature range. With this configuration, the sheet material 1 can be heat-treated to impart appropriate properties (such as strength) to the functional mat X.

[0056] In the embodiment shown in Figure 5(a), the heating unit 6 is a heating roller 61. The heating roller 61 is a pair of rollers that grip the functional mat X, which is fed by the feeding device 3, in the same way as the clamping roller 32. Each roller is a cylindrical or tubular member having a pivot axis in the width direction of the sheet material 1. Furthermore, it is possible to heat the surface portion that can come into contact with the sheet material 1 by rotation, and the heat from this surface portion is conducted to the sheet material 1, thereby heating the sheet material 1.

[0057] Furthermore, the heating roller 61 may be configured to allow for changes in the distance between the pair of rollers. This configuration allows the upper roller to be moved up and down in the vertical direction, similar to the modification example of the clamping roller 32 described above. With such a configuration, the functional mat X passing between the two rollers can be adjusted to the desired thickness in conjunction with the heat treatment.

[0058] In the embodiment shown in Figure 5(b), the heating unit 6 is a housing-type heating device 62. The housing-type heating device 62 has a path through which the functional mat X, which is fed by the feeding device 3, passes, and heating means (electric heating wire, hot air heater, etc.) above and below the path (at least on one side), and is a device capable of heating the functional mat X by heat transfer or radiation.

[0059] The functional mat X, which undergoes heat treatment through the heating section 6, is preferably in a form in which the sheet material 1 contains low-melting-point fibers 12. As shown in Figure 6(b), the low-melting-point fibers 12 are fibrous members that are blended into the fibers of the sheet material 1 and have the characteristic of having a lower melting point compared to other fibers, and examples include low-melting-point cotton and thermoplastic resin.

[0060] In the functional mat X shown in Figure 6(b), the left figure shows the state before passing through the heating section 6 (i.e., before heat treatment), and the right figure shows the state after passing through the heating section 6 (after heat treatment). In the functional mat X before heat treatment, the sheet material 1 contains low-melting-point fibers 12 inside, and the low-melting-point fibers 12 are intertwined with other fibers of the sheet material 1. When this functional mat X is appropriately heated, only the low-melting-point fibers 12 melt, and when the functional mat X is then cooled, the melted low-melting-point fibers 12 fix to some of the fibers of the sheet material 1, improving its strength. This makes it possible to improve the strength of the manufactured functional mat X.

[0061] The heating unit 6 is preferably configured to have a thermometer capable of measuring its own temperature or the surface temperature of the functional mat X. This allows the heating process to be performed while maintaining a temperature range that does not damage the sheet material 1, and also makes it easier to maintain a temperature range in which only the low-melting-point fibers 12 melt. Furthermore, it is more preferable that the heating unit 6 has a system that can automatically control the intensity of heating by the heating unit 6 by feeding back the temperature data acquired by the thermometer.

[0062] In this embodiment, the heating unit 6 is shown as being integrated with other components of the manufacturing apparatus Z in Figures 5(a) and 5(b). However, the heating unit 6 may also be configured as a separate and independent component. This allows for the separation of the process of sandwiching the porous body 2 between the sheet material 1 and the process of heat-treating the functional mat X, thereby increasing the flexibility of the manufacturing process.

[0063] The following describes in detail the method of carrying out the present invention with reference to the drawings. Furthermore, the method of carrying out the invention described below is merely an example, and is not limited to this method; the order of the steps may also be changed.

[0064] ≪Implementation Method≫ After the sheet material 1 is connected in the entanglement device 5, or in conjunction with the start of operation of the feed device 3, the user operates the heating unit 6 to heat-treat the functional mat X, particularly the sheet material 1. At this time, the user adjusts the temperature of the heating unit 6 so that it is within an appropriate temperature range in which only the low-melting-point fibers 12 melt. As a result, only the low-melting-point fibers 12 inside the sheet material 1 melt and connect the surrounding fibers, and after passing through the heating unit 6 they solidify, improving the strength of the sheet material 1. [Explanation of symbols]

[0065] X Functional Mat Y Insole Z manufacturing equipment 1 Sheet material 11 Cross-linked fibers 12 Low melting point fibers 2. Porous material 3. Feed device 31 Feed Roller 32 Clamping rollers 33. Winding roller 34 Directional Roller 4 Spraying equipment 41 Hopper 411 Storage section 412 Outlet 42 Spray volume adjustment member 421 Holding part 43. Finishing member 44 slopes 5 Entanglement device 51 Drive unit 52 Needles 521 Needle body 522 Protrusion 6 Heating section 61 Heating rollers 62. Enclosure-type heating device P adjustment section

Claims

1. A manufacturing apparatus for producing a functional mat in which a granular porous body is sandwiched between two or more sheet materials containing low-melting-point fibers, The device comprises a feeding device that moves the sheet material in a predetermined direction and sandwiches the porous body between the sheet material, a dispensing device that scatters the porous body on one surface of the sheet material, an entanglement device that intertwines and connects the sheet materials that sandwich the porous body, and a heating unit capable of heat-treating the functional mat. The feeding device has clamping rollers that sandwich the porous body between the sheet materials, The spraying device has an adjustment unit that can adjust the amount of the porous material being sprayed, The entanglement device is provided downstream of the clamping roller and upstream of the heating section. The aforementioned heating unit is a housing-type heating device, which is part of the manufacturing apparatus.

2. The aforementioned spraying device has a hopper, The adjustment unit is provided with a dispensing amount adjustment member at the discharge port of the hopper. The manufacturing apparatus according to claim 1.

3. The aforementioned spray amount adjustment member is a rotating body that can rotate about one pivot axis, and on its outer surface, The porous material is provided with a retaining portion capable of holding the granules. The manufacturing apparatus according to claim 2.

4. The adjustment unit is further provided with a position-adjustable measuring member in the gap between the discharge port and the spray volume adjustment member. The manufacturing apparatus according to claim 2.

5. A method for producing a functional mat comprising sandwiching a granular porous body between two or more sheet materials containing low-melting-point fibers, A spraying step of spraying the porous material onto one surface of the sheet material, A feeding step in which the sheet material is moved in a predetermined direction and the porous body is clamped by a clamping roller, An entanglement step in which the sheet materials sandwiching the porous body are intertwined and connected, The heating step includes heating the functional mat using a housing-type heating device, The entanglement process is performed after the porous body is sandwiched between the sheet material and before the heat treatment. A manufacturing method wherein the spraying step further includes a spraying amount adjustment step that allows the amount of porous body sprayed to be adjusted by a spraying device having an adjustment unit.

6. A method for manufacturing an insole including a functional mat in which a granular porous body is sandwiched between two or more sheet materials containing low-melting-point fibers, A spraying step of spraying the porous material onto one surface of the sheet material, A feeding step in which the sheet material is moved in a predetermined direction and the porous body is clamped by a clamping roller, An entanglement step in which the sheet materials sandwiching the porous body are intertwined and connected, A heating step in which the functional mat is heat-treated by a housing-type heating device, A cutting process for cutting the functional mat into a predetermined shape, The process includes a suturing step of suturing the peripheral edge of the cut-out functional mat, The entanglement process is performed after the porous body is sandwiched between the sheet material and before the heat treatment. A manufacturing method wherein the spraying step further includes a spraying amount adjustment step that allows the amount of porous body sprayed to be adjusted by a spraying device having an adjustment unit.

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