CN111511656A - Method for manufacturing filter molded product - Google Patents
Method for manufacturing filter molded product Download PDFInfo
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- CN111511656A CN111511656A CN201880082082.5A CN201880082082A CN111511656A CN 111511656 A CN111511656 A CN 111511656A CN 201880082082 A CN201880082082 A CN 201880082082A CN 111511656 A CN111511656 A CN 111511656A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D77/00—Packages formed by enclosing articles or materials in preformed containers, e.g. boxes, cartons, sacks or bags
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Abstract
The invention provides a method for manufacturing a filter molded product, which realizes cutting and welding at the same time by using laser and has high manufacturing efficiency. Another object of the present invention is to provide a filter molded article with a new service method that has not been available in the past by effectively utilizing a manufacturing method of a filter molded article with high manufacturing efficiency. The method for manufacturing a filter molded product of the present invention includes: a heat welding step of overlapping two or more filters and applying heat to the two or more filters to weld the two or more filters; and a molding step of simultaneously cutting and welding the filter after the heat welding step by using laser.
Description
Technical Field
The present invention relates to a method for manufacturing a filter molded product using a laser processing technique.
Background
So-called tea bags, in which a raw material such as tea, coffee, or soup is sealed in an extraction filter and an extract liquid can be easily obtained by merely immersing the raw material in hot water, are mostly rectangular or triangular pyramid-shaped from the viewpoints of ease of molding and extraction efficiency.
On the other hand, patent document 1 discloses a heart-shaped, star-shaped, fruit-like, or animal-like shaped tea bag as a filter molded product having a peculiar shape.
Patent document 1 discloses a method of manufacturing such a filter molded product having a peculiar shape, in which a filter is sandwiched between a base and a mold, and the filter is cut and welded in a predetermined shape by using a fusion cutting tool that emits ultrasonic waves.
However, the method described in patent document 1 has not been automated yet, and has a problem that it needs to be performed manually, and the manufacturing efficiency is poor.
Further, in the contact type tool such as the fusion cutting tool described in patent document 1, there is a problem that the overlapping of the filters is deviated or scattered, and it is difficult to simultaneously perform cutting and welding in a desired accurate shape.
Further, the mold is expensive, and if the mold is prepared for each shape, a high cost is required.
In addition, in ultrasonic welding, if the filter is in a straight and simple shape as in a conventional filter molded product such as a tea bag, welding can be performed while cutting the filter, but it is known that sufficient welding and cutting cannot be performed for a complicated shape such as a heart-shaped curve or a star-shaped tip portion, which causes content loss. Further, since the welding cannot be performed neatly and accurately, the shape is defective.
Patent document 2 describes the following method: as a method for producing a filter molded product having a peculiar shape, a filter is cut into a predetermined outer shape in advance, and two pieces of the filter are overlapped and sewn at a predetermined pitch to such an extent that tea leaves do not flow out.
However, if the filter is sewn with only thread as in the method described in patent document 2, the thread is loosened with time, and thus there is no problem in individual manufacture and use, but it is not suitable for mass production.
Further, if the filter is cut in advance into a predetermined outer shape, there is a problem that additional labor and cost are required.
Documents of the prior art
Patent document
Patent document 1: japanese utility model registration No. 3116503
Patent document 2: japanese patent laid-open publication No. 2013-133108
Disclosure of Invention
Problems to be solved by the invention
However, in order to ensure the stability of the filter when manufacturing a filter molded article having a special shape, it is obvious to overlap the filter to increase the thickness.
However, when the thickness of the filter is increased by the conventional method to stabilize the filter, there are problems in terms of production efficiency and appearance of the molded product.
The present inventors focused on the laser processing technology and established a method for producing a filter molded article, which has higher production efficiency than conventional methods and can be easily produced even when the filter has a peculiar shape.
The present inventors have considered that if a laser processing technique is used, cutting and welding of a filter can be performed at the same time, and the processing speed is also high, thereby improving the manufacturing efficiency, and therefore, they have conducted intensive studies repeatedly.
However, contrary to expectation, it is difficult to simultaneously achieve cutting and welding of the filter using only the laser processing technique.
It is known that the laser needs to be focused in order to cut the filter cleanly, but the filter cannot be welded smoothly at the time of focusing, and a gap is left.
On the other hand, it is known that if the focal point is widened, welding can be performed without a gap, but cutting cannot be performed neatly, and the shape is deformed.
In view of the above-described problems, an object of the present invention is to provide a method for manufacturing a filter molded article, which realizes cutting and welding simultaneously using a laser and has high manufacturing efficiency.
Another object of the present invention is to provide a filter molded article having a novel conventional mode of use, which is obtained by effectively utilizing a method for producing a filter molded article with high production efficiency.
Means for solving the problems
The method for manufacturing a filter molded product according to the present invention for solving the above problems includes:
a heat welding step of overlapping two or more filters and applying heat to the two or more filters to weld the two or more filters; and
and a molding step of cutting and welding the filter after the thermal welding step by using laser.
According to the present invention, first, by applying heat to two or more filters, the filters are welded to each other to such an extent that they can be easily peeled off by hand.
Then, by using a laser for the filter in this state, cutting and welding can be performed simultaneously, and a filter molded product having a predetermined shape can be easily manufactured.
In a preferred embodiment of the present invention, the temporary fixing step includes: after the heat-welding process and before the molding process, it is temporarily fixed by sewing and/or ultrasonic waves to define a predetermined shape. Although the cutting and welding can be simultaneously performed by only the heat welding step, it is preferable to have the above-described temporary fixing step when the filter molded product is finished to a finished product having a more neat finish.
In a preferred embodiment of the present invention, the method comprises a raw material charging step: after the heat welding step, a part of the filter is peeled off, and the raw material is charged.
When a filter molded product is used as a tea bag, if a raw material is sandwiched before a heat-welding step, the raw material is displaced by vibration in the heat-welding step and the molding step, and the mass distribution of the raw material varies for each product.
The above problems can be solved by adopting a preferred mode of the present invention.
The filter may be any filter that can extract the components of the enclosed raw material using a liquid such as hot water or water, and is preferably at least one selected from paper, nonwoven fabric, nylon yarn, polyester yarn, and biodegradable fibers of plant origin.
The present invention for solving the above problems is an assembled filter molded product having the filter molded product manufactured by the above manufacturing method as a component.
The filter molded product of this type can be assembled by consumers before use. Further, the assembled filter molded product can be appreciated and enjoyed.
In a preferred embodiment of the present invention, the assembled filter molded product is an assembled filter molded product in the form of a plastic mold (プラモデル) having a runner portion, a gate portion, and a part portion.
In this type of filter molded product, the consumer can enjoy a self-assembly process before use. Further, the assembled filter molded product can be appreciated and enjoyed.
In a preferred aspect of the present invention, the assembled filter molded product is an assembled filter molded product having an expanded view shape of a predetermined three-dimensional shape.
The filter molded product of this type can be assembled by consumers before use. In addition, the material can also be used as teaching materials for children.
In a preferred aspect of the present invention, the assembled filter molded product is a block-shaped assembled filter molded product having a jigsaw puzzle shape.
The filter shaped article in this form can be used by consumers to enjoy the process of completing a jigsaw puzzle before use. In addition, it may help educate children.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the manufacturing method of the present invention, a filter molded product can be efficiently manufactured.
The filter molded product of the present invention is provided with a new mode of use.
Drawings
Fig. 1 is a reference view of a use state of a hook tag.
Fig. 2 is a substitute photograph for a drawing of a heart-shaped filter molded product (comparative example 1) produced by stacking two filters and cutting and welding the stacked filters with a laser without performing a heat welding step.
Fig. 3 is a substitute photograph for a drawing of a heart-shaped filter molded product (comparative example 1) produced by stacking two filters and cutting and welding the stacked filters with a laser without performing a heat welding step.
Fig. 4 is a substitute photograph for a drawing of a heart-shaped filter molded product (comparative example 1) produced by stacking two filters and cutting and welding the stacked filters with a laser without performing a heat welding step.
Fig. 5 is a substitute photograph for a drawing of a heart-shaped filter molded product (example 1) produced by stacking two filters, and performing cutting and welding with a laser through a thermal welding process.
Fig. 6 is a substitute photograph for a drawing of a heart-shaped filter molded product (example 1) produced by stacking two filters, and performing cutting and welding with a laser through a thermal welding process.
Fig. 7 is a substitute photograph for a drawing of a heart-shaped filter molded product (example 1) produced by stacking two filters, and performing cutting and welding with a laser through a thermal welding process.
Fig. 8 is a substitute photograph for a drawing of an assembled filter molded product in the form of a plastic mold according to the present embodiment.
Fig. 9 is a photograph showing a substitute for a drawing of a finished product in which the assembly type filter molded product in the form of a plastic mold according to the present embodiment is assembled.
Fig. 10 is a schematic view showing an assembled filter molded article in the form of a development figure which can form a cube according to the present embodiment.
Fig. 11 is a schematic view showing an assembled filter-formed article in the form of an expanded view that can form an octahedron according to the present embodiment.
Fig. 12 is a schematic view showing an assembled filter molded article in the form of a development figure that can be formed into a cube, having an insertion portion, according to the present embodiment.
Fig. 13 is a schematic view showing an assembled filter molded article in the form of a puzzle according to the present embodiment.
Detailed Description
Hereinafter, a filter molded product and a method for manufacturing the filter molded product according to an embodiment of the present invention will be described in detail, but the present invention is not limited thereto.
(1) Filter formed product
In the present specification, the filter molded product is a generic term for a product obtained by processing and molding a filter.
Examples of the filter molded product include an extraction filter such as a tea bag, and a label portion (hook label) of a type suspended at the rim of a cup (see fig. 1).
In the conventional method for manufacturing a filter molded product according to the present invention, the extraction filter portion and the label portion can be manufactured using the same material and the same production line, and thus the manufacturing process can be simplified and the cost can be reduced.
The material of the filter used in the filter molded product of the present invention is not particularly limited, and is preferably at least one selected from paper, nonwoven fabric, nylon yarn, polyester yarn, and biodegradable fiber derived from a plant.
According to the embodiment of the present invention, a filter molded product using a filter made of a plurality of materials may be used.
(2) Method for manufacturing filter molded product
The method for manufacturing the filter forming product comprises the following steps: two or more filters are stacked, and the two or more filters are heat-welded.
The method of applying heat is not particularly limited, and ultrasonic welding, hot air welding, hot plate welding, impulse welding, soldering welding, and the like can be used.
The above-described method of applying heat and the temperature of the applied heat are different depending on the kind of the filter, and may be appropriately changed and adjusted by those skilled in the art.
For example, if the filter is a nonwoven fabric, welding can be performed by applying heat of 140 ℃ to 240 ℃.
Preferably, the welding is performed by applying heat of 160 ℃ to 200 ℃. By applying heat in such a temperature range, welding can be performed more neatly.
The number of sheets of the overlapped filter is not particularly limited, and can be appropriately changed according to the required strength.
When the filter molded product is an extraction filter, the number of stacked filters is preferably 10 or less, more preferably 8, and even more preferably 6 or less, from the viewpoint of extraction efficiency.
The heat-welding step may be performed on the entire surface of the filter or may be performed only on a predetermined portion to be cut by a laser beam, which will be described later.
When the filter is a nonwoven fabric, if the surface (front surface) of the mesh is thick and the surface (back surface) of the mesh is thin, and the surfaces of the filters are joined together and heat is applied, the filter is welded to such an extent that the filter is not easily peeled off by a human hand, and if heat is applied by joining the surface of the filter and the back surface of another filter, the filter is welded to such an extent that the filter is easily peeled off by a human hand.
When the produced filter molded product is the above hook label, it is preferable that the surfaces of the filters are joined and heat-welded.
By adopting this form, the filters are not easily peeled off from each other, and a hook label with high stability can be manufactured.
When the filter molded product is an extraction filter such as a tea bag, it is preferable that the surface of the filter and the back surface of the other filter are joined together and heat-welded to each other.
In this way, an extraction filter in which a raw material described later can be easily sealed can be manufactured.
The method for manufacturing a filter molded product of the present invention includes a molding step: the filter after the above-described heat welding process is cut and welded by using a laser.
By using a laser after the thermal welding process, the cutting and welding of the filter can be performed at the same time, and as a result, the manufacturing efficiency is significantly improved. Further, the finish after cutting is uniform, and the filter can be easily manufactured even for a filter molded product having a complicated shape.
As the laser used in the method for producing a filter molded article of the present invention, a solid laser and a gas laser generally used for machining and welding can be used, and CO is preferably used2And (4) laser.
The upper limit and the lower limit of the output of the laser light differ depending on the kind of the filter, and can be appropriately adjusted by those skilled in the art.
For example, when the filter is a nonwoven fabric, the lower limit of the output of the laser is preferably 10W or more, more preferably 15W or more, and particularly preferably 20W or more. The upper limit of the output of the laser beam is preferably 150W or less, more preferably 140W or less, and still more preferably 130W or less.
In one embodiment of the present invention, the temporary fixing step includes: after the thermal welding process and before the molding process, the filter is temporarily fixed by sewing and/or ultrasonic waves so as to be defined into a predetermined shape.
By cutting and welding the inner and outer 2mm portions of the position provisionally fixed in the provisional fixing step with a laser, a filter molded product having a more complicated shape can be easily produced. Further, since the displacement of the filters from each other is suppressed, the cut surfaces become neat and the appearance becomes more beautiful.
The stitching may be performed by hand stitching or by a sewing machine. In the case of performing sewing, it is preferable to use a sewing machine programmable to sew into a predetermined shape from the viewpoint of manufacturing efficiency.
As the ultrasonic welding, a device generally used for welding a filter can be used, and examples thereof include a sealer type device, a pen type device, a programmable ultrasonic pen, an ultrasonic sewing machine, and the like.
In one embodiment of the present invention, the method comprises a raw material charging step: after the heat-welding step, a part of the welded filter is peeled off to form an inlet, and the raw material is introduced from the inlet.
Since the filters can be peeled off from each other with a small force after the heat-fusion step, the use of such a structure can prevent the occurrence of a shift due to vibration of the raw material during the production and the like, which causes a problem of a difference in the quality of the raw material for each product.
Here, the raw material in the present specification means a substance that exerts an effect by being put into a filter, and examples thereof include: ingredients contained in raw materials for dissolution or extraction such as tea leaves, coffee, chinese medicines, soy sauce soup, sports drinks, and soup, ingredients contained in miscellaneous goods such as aromatic materials and aroma chemicals, and ingredients used in stones, ores, deodorants, and odor preventives, which are used for purposes of providing hot spring performance when put in a bath.
In the method for producing a filter molded product according to the present invention, the step of charging the raw material is not essential, and for example, a filter molded product having an empty content may be produced so that a user can charge a desired raw material.
When three or more filters are stacked and a filter molded product for extraction is produced, it is preferable that the raw material is sealed in the outermost filter and the next filter.
By adopting such a form, it is possible to suppress a decrease in extraction efficiency due to overlapping of a plurality of filters.
Fig. 2 to 4 show a heart-shaped filter molded article (comparative example 1) produced by stacking two filters and cutting and welding the stacked filters using a laser without performing the above-described heat welding step.
Fig. 5 to 7 show a heart-shaped filter molded article (example 1) produced by stacking two filters, and performing cutting and welding using a laser after the above-described heat welding step.
As shown in fig. 3, in comparative example 1, the concave portion on the upper side of the heart shape was not welded.
In comparative example 1, as shown in fig. 4, the right side surface portion of the heart shape was not welded.
On the other hand, as shown in fig. 6 and 7, in example 1, the filters were well welded to each other, and there were no open parts.
As is apparent from these results, according to the method for producing a filter molded article of the present invention, cutting and welding by laser can be simultaneously achieved, and as a result, the filter molded article can be produced with high production efficiency.
The present invention also provides an assembled filter molded article comprising the filter molded article produced by the above-described production method as a component.
Hereinafter, an example of the assembled filter molded product of the present invention will be described in detail.
(3) Assembled filter forming product
One embodiment of the filter molded product of the present invention is a plastic mold type built-up filter molded product 10 (see fig. 8 and 9) made of nonwoven fabric, which can be used to manufacture a crane 14.
The plastic mold type filter assembly 10 according to the present embodiment includes a runner portion (ランナー)11, a gate portion 12, and a component portion 13.
The runner section 11 is a frame portion of the assembled filter molded product 10 in the form of a plastic mold.
The gate portion 12 is a portion connecting the runner portion 11 and the component portion 13 or the component portion 13 of the assembled filter molded product 10 in the form of a plastic mold to each other.
The part 13 is a member for constructing the crane 14.
The assembled filter molded product 10 in the form of a plastic mold according to the present embodiment is an extraction filter, and a user puts tea leaves that the user likes into the body portion 13 a.
The assembled filter molded product 10 in the plastic mold form according to the present embodiment can complete the crane 14 by separating the component part 13 from the gate part 12 and folding each component part 13 into a predetermined shape.
The plastic model type filter molded product 10 of the present invention is not limited to the present embodiment, and may be configured to have a part portion having various shapes in addition to the shape of a crane, such as imitating various shapes of other animals, vehicles, plants, buildings, and clothes.
The plastic mold type filter-assembled product 10 of the present invention may be in a form in which the content is empty so that a user can enclose a desired material as in the present embodiment, or in a form in which a material is enclosed in one or two or more component parts.
The plastic molded filter product 10 of the present invention may be assembled by, for example, increasing the number of stacked filters, increasing the thickness, and inserting parts, without the need for a structure in which the parts are folded.
The plastic molded filter assembly 10 of the present invention may be formed in a predetermined shape by heat-fusing the component parts 13 to each other.
One embodiment of the filter molded product of the present invention is an assembled filter molded product 20 (see fig. 10 and 11) in an expanded view having an outer shape of a predetermined three-dimensional shape in an expanded view.
Fig. 10 shows a schematic view of filter moldings 20a and 20b assembled in the form of a development pattern which can be assembled to form a cube 21.
Fig. 11 shows a schematic view of assembled filter moldings 20c and 20d in the form of development patterns which can be assembled to form an octahedron 22.
The filter molded product 20 of the present invention is not limited to this, and may be in the form of a developed pattern such as a prism, a pyramid, a cylinder, a cone, or a polyhedron.
The shapes of the developed cubic and octahedral shapes are not limited to those shown in fig. 10 and 11, and various shapes can be used.
The filter molding 20 assembled in the expanded view type may have an insertion portion 23 for easy assembly (see fig. 12).
The filter molded product 20 of the development pattern type may have an insertion opening at a predetermined position and be inserted into the insertion portion 23 (not shown).
The filter molded product 20 of the development pattern type of the present invention may be in a form in which a user seals a desired material in an internal space generated by assembling a three-dimensional shape, or in a form in which a material is sealed between a plurality of filters stacked in the filter molded product 20 of the development pattern type.
The form in which the raw material is sealed between the filters can be exemplified by a form in which the raw material is sealed in at least one of the portions corresponding to the respective faces of the cube in an assembled filter molded product in the form of a developed view of the cube, for example.
One embodiment of the filter molded product of the present invention is a jigsaw puzzle type assembled filter molded product 30 (fig. 13) having a puzzle-like block shape.
The assembled filter molded body 30 of the puzzle type can be assembled into a puzzle 31 by combining them.
The shape of the assembled filter molded body 30 of the puzzle type is not particularly limited, and may be any shape as long as it can be fitted like a puzzle as shown in fig. 13.
The shape of the puzzle 31 completed by assembling the puzzle-type assembled filter molded body 30 is not particularly limited.
For example, the shape of the puzzle 31 may be a shape that simulates an animal, a vehicle, a plant, a building, clothing, or the like.
The jigsaw type filter molding 30 may be in a form in which the content is empty so that the user can seal in a desired material, or in a form in which a material is sealed.
As for the form of enclosing the raw material, for example, such a form can be adopted: the colored material is sealed in the puzzle-type assembled filter molded product 30, and a predetermined pattern appears in the completed puzzle 31.
The assembled filter-molded product 30 of the tile type may be manufactured as one block-shaped part, but it is preferable to manufacture the filter by cutting and welding the filter into blocks after cutting and welding the filter into a shape having the assembled tile 31 using laser.
By using this method, a filter molded product assembled in a pattern can be easily produced.
The assembled filter molded product of the present invention may be an assembled filter molded product obtained by combining one or more of the plastic mold type assembled filter molded product, the developed pattern type assembled filter molded product, and the jigsaw pattern type assembled filter molded product.
Industrial applicability
The present invention can be applied to the production of various filter molded products which are widely varied.
Description of the reference numerals
10 plastic model type assembled filter forming product
11 flow channel part
12 gate part
13 parts section
13a torso part
13b wing part
13c face/tail
14 crane
20 expansion pattern type assembled filter forming product
20a assembled filter molded article in the form of a developed pattern in a cube
20b assembled filter molded article in the form of a developed figure forming a cube
20c octahedron-formed expansion pattern type assembled filter molding
20d octahedron-formed expansion pattern type assembled filter molding
21 cube
22 octahedron
23 insertion part
30-splicing pattern type assembled filter forming product
31 jigsaw puzzle
Claims (8)
1. A method for manufacturing a filter molded product, comprising:
a heat welding step of overlapping two or more filters and applying heat to the two or more filters to weld the two or more filters; and
and a molding step of cutting and welding the filter after the thermal welding step by using laser.
2. The method of manufacturing a filter molded product according to claim 1, comprising a temporary fixing step of: after the heat-welding process and before the molding process, it is temporarily fixed by sewing and/or ultrasonic waves to define a predetermined shape.
3. The method of manufacturing a filter molded product according to claim 1 or 2, comprising a raw material charging step of: after the heat-welding step, a part of the temporarily fixed filter is peeled off, and the raw material is charged.
4. The method of manufacturing a filter molded product according to any one of claims 1 to 3, wherein the filter is at least one or more selected from paper, nonwoven fabric, nylon yarn, polyester yarn, and biodegradable fiber of plant origin.
5. An assembled filter molded article comprising, as a component, the filter molded article produced by the production method according to any one of claims 1 to 4.
6. The filter assembly of claim 5, wherein the filter assembly is in the form of a plastic mold having a runner portion, a gate portion, and a part portion.
7. The assembled filter molded product according to claim 5, wherein the outer shape is an expanded view shape of a predetermined three-dimensional shape.
8. The modular filter assembly of claim 5, wherein the shape is a puzzle block.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2018-002252 | 2018-01-10 | ||
| JP2018002252A JP6386681B1 (en) | 2018-01-10 | 2018-01-10 | Manufacturing method of filter molded products |
| PCT/JP2018/043713 WO2019138717A1 (en) | 2018-01-10 | 2018-11-28 | Method for manufacturing filter molded product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN111511656A true CN111511656A (en) | 2020-08-07 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201880082082.5A Pending CN111511656A (en) | 2018-01-10 | 2018-11-28 | Method for manufacturing filter molded product |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP6386681B1 (en) |
| CN (1) | CN111511656A (en) |
| WO (1) | WO2019138717A1 (en) |
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|---|---|---|---|---|
| JP3216700U (en) * | 2018-04-06 | 2018-06-14 | 株式会社オフィス・タカハシ | Acrylic original jigsaw puzzle |
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- 2018-01-10 JP JP2018002252A patent/JP6386681B1/en active Active
- 2018-11-28 WO PCT/JP2018/043713 patent/WO2019138717A1/en active Application Filing
- 2018-11-28 CN CN201880082082.5A patent/CN111511656A/en active Pending
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Also Published As
| Publication number | Publication date |
|---|---|
| JP2019119513A (en) | 2019-07-22 |
| WO2019138717A1 (en) | 2019-07-18 |
| JP6386681B1 (en) | 2018-09-05 |
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