CN1119237C - Method and apparatus for moulding fibre mixture - Google Patents
Method and apparatus for moulding fibre mixture Download PDFInfo
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- CN1119237C CN1119237C CN98127127A CN98127127A CN1119237C CN 1119237 C CN1119237 C CN 1119237C CN 98127127 A CN98127127 A CN 98127127A CN 98127127 A CN98127127 A CN 98127127A CN 1119237 C CN1119237 C CN 1119237C
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Abstract
The present invention relates to a method and a device for molding a buffer element by a fiber mixture through a filling process and a heat treatment process. The filling process comprises the step that the fiber mixture composed of synthesized precursor fibers and adhesive fibers dispersed in the synthesized precursor fibers is filled in a mold cavity of a ventilation property mold through the action of airflow transmission. The heat treatment process comprises the step that molding airflow of the fiber mixture filled in the mold cavity in the mode of heating and/or cooling is circulated through the fiber mixture, the surface of a mold in contact with the fiber mixture is divided into a plurality of contact surfaces, and the airflow in the mold cavity is differently controlled in the filling process and the heat treatment process by a method that the flow speed of the airflow of each contact surface and/or the pressure is adjusted to a preset condition.
Description
The present invention relates to method and apparatus by the molded buffer element of fibre blend, this fibre blend is precursor fiber that synthesizes and the mixture (after this being called " fibre blend ") that is dispersed in the binder fiber (its fusing point is lower than the fusing point of precursor fiber) in the precursor fiber, and fibre blend wherein is loaded into die cavity and is heated there.In particular, the present invention relates to a kind of method and apparatus by the molded buffer element of fibre blend, this method comprises the steps: under the effect of delivery air fibre blend packed in the die cavity that is formed by air-permeable mold, will be used at last heating and/or the molded air-flow that cools off feeds the fibre blend that is full of.
In general, polyurethane foam plastics can be widely used in and form the seat cushion buffer element that has labyrinth on automobile or the aircraft cheaply., polyurethane foam plastics has its shortcoming, can produce poisonous gas and reclaim also very difficultly in combustion process, and therefore, people are thirsting for finding a kind of substitute always for a long time.
In order to address the above problem, people have noticed and have used the buffer element of above-mentioned fibre blend as the substitute of polyurethane foam plastics recently.Thereby the sort buffer element is to be contained in binder fiber in the fibre blend with fusion and will to form each fiber of fibre blend and be connected to each other and form together by inserting fibre blend in the die cavity and heating this fibre blend.
In addition, be also to propose a kind of method of producing buffer element among Nos.2-95838 and the 7-324266 for example with fibre blend at the Japanese unexamined patent publication No. publication number, wherein fibre blend be accompanied by delivery air insert in the mould that constitutes by poromeric material and the fibre blend that hot-air and cold air flow through be filled in the die cavity with molded buffer element.The advantage of this method is because hot-air and cold air flow through fibre blend, so that buffer element is heat-treated fast and equably becomes possibility.
; also there is a problem according to above-mentioned method of moulding; if buffer element has complex configuration as shown in Figure 1; for example Fig. 1 is the backrest of an automotive seats; have a bag shape structure F at an upper portion thereof and have a vertical wall D, so just can not obtain high-quality buffer element in corresponding both sides.This is because fibre blend is inserted in the process of die cavity under the delivery air effect, the delivery air conditions needed is different from passes through fibre blend (in this respect with hot-air and/or cold air, " hot-air and/or cold air " and " molded air-flow " has identical implication in the present invention) process in, molded air-flow conditions needed.This will describe in detail below.
Fibre blend is being inserted in the process of die cavity, required in die cavity, not produce because of lacking hole and the fibre blend that fibre blend forms and fill with the bulk density of being scheduled to.Therefore just must revise mould for use in the easier part that in die cavity, is easy to produce the hole that enters of the delivery air of fibre blend.Be to realize this purpose, the gas permeability that is easy to produce that part of die cavity in hole in die cavity must be higher than the gas permeability of die cavity other parts.
On the contrary, molded air communication is being crossed in the heat treatment process that is filled in the fibre blend in the die cavity, need be with molded air-flow equably the mould by being filled with fibre blend so that in formed buffer element, there is not molded inhomogeneities to take place.
From top description obviously as can be seen, acting between filling process and the heat treatment process of air-flow is very different in die cavity, wherein, in filling process fibre blend be little by little charge into die cavity and in heat treatment process fibre blend be full of die cavity.
In addition, unless the shape condition of molding that the shape of the die cavity in filling process is different from die cavity in heat treatment process usually is unique especially.This be because when fibre blend is being filled owing to its bulk density is lower, so thereby the bulk density that must move moulds on compression direction and obtain being scheduled to the extrusion fiber mixture just, and this will cause the difference on mold cavity configuration between filling process and the heat treatment process naturally.
As mentioned above, in filling process and heat treatment process, the structure that acts on its die cavity of air-flow in the required die cavity, air communication is crossed the flow resistance of fibre blend, and the path of air current flow or others are different.That is to say that the effect that need be used for the delivery air of conveying fiber mixture has different performances with need being used for fibre blend is transformed between the effect of molded air-flow of buffer element.Therefore, filling inhomogeneities that obtains high-quality buffer element and can avoid simultaneously being produced with the conventional molded method and/or heat treated inhomogeneity are very difficult, in traditional method of moulding, although the gas permeability of mould is that the desired performance gap of constant between is very big in filling process and heat treatment process.
This situation can be brought a serious problem in a large amount of production processes of buffer element, because need the long time (for example 30 minutes) slowly to increase and reduce the temperature of fibre blend to avoid the inhomogeneity in heat treatment process, thereby thereby caused molded overlong time to reduce the speed of producing in batches, increased production cost.
In order to address the above problem, it is that a large amount of molded air communication is crossed fibre blend to improve the heat transference efficiency that flows to fibre blend from molded gas that a kind of scheme is arranged., this method will be attended by the rising of air pressure simultaneously but needing molded air-flow to have bigger flow rate.Therefore, fibre blend through heating can be lost its elasticity to a certain extent, will make fibre blend easy deformation under more atmospheric influence like this, so, thereby the thickness of resultant product is than the thin quality that reduces buffer element of desired thickness.
For fear of the generation of this problem, the flow rate of quickening hot-air reaches softening point up to the temperature of binder fiber, and lowering the speed that flows in softening back then also is that people are thinkable.In cooling procedure, the cold air that uses low speed to flow when fibre blend is in fusion or soft state (at this moment easily deforming) quickens flowing of cold air at once when deforming hardly.Although this method is effectively for shortening process time to a certain extent, can not reduce the heat treatment time of heating/cooling significantly.Therefore, be difficult to shorten the molded time of buffer element, for example shorten to 5 minutes or still less; And also the high-quality mass-produced cost that reduces simultaneously can not kept.
For the mould of the buffer element of molded labyrinth, the mould of molded backrest shown in Figure 1 for example is used for the die cavity of fiberfill fibers mixture and also must correspondingly has complicated configuration.Therefore, when fibre blend all was accompanied by delivery air and is packed in the die cavity, the behavior of delivery air in die cavity was difficult to control.Thereby prevent that the hole from producing when being difficult in the fiberfill fibers mixture.Therefore very difficult control will be filled into the fiber in the die cavity, makes it be in desirable state.
In order to solve the problems referred to above in the prior art, an object of the present invention is to provide a kind of method by the molded buffer element of fibre blend, even buffer element has complicated structure, this method also can be avoided inhomogeneities in the filling process and the inhomogeneity in the heat treatment process and can reduce the molded time, also can obtain good production efficiency and quality.
As the means that realize the object of the invention, a kind of method of moulding now is provided, air-flow is wherein controlled respectively in filling process and heat treatment process, and this method is to be divided into a plurality of contact-making surfaces and to change air current flow speed by each contact-making surface (mold wall) and/or pressure and consistent with predetermined condition by the mould contact surface (mold wall) that will be filled with fibre blend in the die cavity.Particularly, the invention provides a kind of method by the molded buffer element of fibre blend, use a kind of air-permeable mold with the contact surface of fibre blend that has, wherein contact surface is divided into a plurality of contact-making surfaces, this method may further comprise the steps: will be inserted in the die cavity of air-permeable mold by the effect of the delivery air that passes through contact-making surface of filling usefulness by the opening fiber mixture that synthetic precursor fiber and binder fiber are formed, the fibre blend in the die cavity is inserted in compression, a heat treatment step, comprise and make molded air communication cross contact-making surface, so that the heating fibre blend is used for bond vitrified agent fiber, with the fibre blend that then cools off through heating, make the binding agent of fibre blend and fusion integrated, it is characterized in that, flow velocity and/or the pressure carrying and fill air-flow are controlled by contact-making surface, and the flow velocity and/or the pressure of the air-flow by each contact-making surface divide other control in filling process and heat treatment process.
In addition, also provide a kind of device that is used to realize above-mentioned method of moulding.Be a kind of device by the molded buffer element of fibre blend, this fibre blend is made up of synthetic precursor fiber and the binder fiber that is dispersed in wherein, and this device comprises: hot-air generator; Have an air-permeable mold with the contact surface of fibre blend, described contact surface is divided into a plurality of contact-making surfaces; Carrier pipe is used for the fibre blend of shredding state is transported to die cavity; Actuating device is used for moving moulds and inserts the fibre blend of die cavity with compression; Hair-dryer and/or exhaust blower are used for air-flow is blown into die cavity and/or therefrom discharges air-flow; It is characterized in that, the flow velocity of the air by each contact-making surface and/or pressure can fill and heat treatment process in control respectively; Comprising also with this device that a control device is used for controlling respectively fills and flow velocity and/or the pressure of heat treatment process by the air-flow of each contact-making surface arrives predetermined condition.
This control realizes in such a way: will be blown into or discharge with control by the air-flow of each contact-making surface (mold wall) through the flow velocity of the air-flow of each contact-making surface and/or pressure to meet predetermined condition or the control flow velocity by the delivery air of contact-making surface (this contact-making surface forms a die cavity), and be greater than the flow velocity of the air-flow that passes through other contact-making surface at the flow velocity of its air-flow of place that fibre blend is difficult to be filled into.
In addition, partly or entirely will being suitable for of contact-making surface (mold wall), can move on the direction of the fibre blend of extrusion packing in die cavity individually, it is up/down, left/right or forward/backward move, and adjust to desired state so that be filled in the bulk density of the fibre blend in the die cavity according to needed performance.Therefore, though each contact-making surface (mold wall) only moves on the direction of one dimension, the fibre blend that is filled in the die cavity can be squeezed on the direction of bidimensional or three-dimensional.This in addition extruding not only can be carried out but also can be carried out the part fibre blend the whole fibre blends that are filled in the die cavity.
In a kind of like this mode, even be used for the die cavity that molded for example lazyback etc. has the buffer element of labyrinth, the flow of optionally controlling delivery air and/or the molded air-flow by contact-making surface (mold wall) is possible.And control is filled in the die cavity bulk density of fibre blend to reach desirable value also is possible partly.Therefore, fibre blend is filled in the die cavity and do not produce and fill inhomogeneous may accomplishing, and when fibre blend was transformed into buffer element by heat treatment, heat treated inhomogeneity also can be eliminated.Therefore, method of moulding proposed by the invention and be used to realize that the device of this method can reduce the molded time and make the buffer element of finally being made by fibre blend have good production efficiency and quality.
Figure 1A, 1B and 1C are schematically illustrating of buffer element 20, this buffer element 20 has complicated structure and has a bag shape structure F at an upper portion thereof, has vertical wall D (for example back cushion of automotive seats) in its corresponding both sides, wherein Figure 1A is the front view of buffer element 20, Figure 1B is the rearview of buffer element 20, and Fig. 1 C is the side view of buffer element 20.
Fig. 2 A, 2B and 2C are respectively the front views that is in the device that is blown into pattern of the moulding fibre mixture according to the present invention, the momentary status of Fig. 2 A before fibre blend is blown into die cavity wherein, Fig. 2 B is the starting stage of under the effect of delivery air fibre blend being inserted, and what Fig. 2 C illustrated is the state that fibre blend is transformed into the molded air-flow of buffer element.
Fig. 3 A and 3B are respectively the side views that is used for the prior-art devices of molded buffer element with vertical wall construction, and wherein, Fig. 3 A has illustrated the state after fibre blend is blown into die cavity and finishes, and Fig. 3 B has illustrated to fibre blend the state after extruding is finished.
Fig. 4 is a stereogram of using the buffer element of the prior art acquisition shown in Fig. 3 A and 3B.
Fig. 5 A and 5B are respectively the side views of apparatus of the present invention, and this device is that mode by lateral compression is by the molded buffer element with vertical wall construction of fibre blend.
Fig. 6 A, 6B and 6C are respectively the front views of device, this device is molded to have the buffer element that labyrinth is made up of fibre blend such as lazyback, wherein, Fig. 6 A has illustrated that fibre blend inserts the filling process of die cavity, what Fig. 6 B and 6C illustrated is heat treatment process, and the direction that wherein is blown into the molded air-flow of die cavity is opposite in two width of cloth figure.
Fig. 7 A and 7B be respectively the extrusion system of prior art in the molded front schematic view that is used for the bulk density of controlling fiber mixture during having the buffer element of complex configuration, wherein Fig. 7 A is the state of die cavity before the extruding, Fig. 7 B is the state of extruding back die cavity.
Fig. 8 A, 8B and 8C are respectively the front schematic view of extrusion system of the present invention that is used for the bulk density of controlling fiber mixture, the first step of Fig. 8 A fiberfill fibers mixture in die cavity wherein, Fig. 8 B second of the fiberfill fibers mixture goes on foot in die cavity after the first step is finished and carried out extruding partly, Fig. 8 C is final step, all there filling steps are all finished, and the fibre blend of extruding has had basically wants the bulk density that obtains.
Fig. 9 A, 9B and 9C be respectively under the effect of delivery air in die cavity the even front schematic view of three systems of fiberfill fibers mixture, wherein Fig. 9 A is the situation with a plurality of fibre blend inlets, Fig. 9 B is another situation, the inlet of its fibre blend is movably on the direction of arrow, Fig. 9 C is another situation, and wherein the inlet of fibre blend can change direction on the direction of arrow.
Composite fibre materials to the precursor fiber that constitutes the present invention's " fibre blend " does not have any restriction, it can comprise such as polyethylene terephthalate, polybutylene terephthalate (PBT), poly terephthalic acid hexylene glycol ester, polybutylene terephthalate (PBT), poly terephthalic acid 1,4-hexamethylene dimethyl ester, staple fibre or its copolymer esters of poly-pivalolactone, the staple fibre of the mixture of staple fibre or the composite fibre (conjugate fiber) formed by two or more above-mentioned component of polymer of mentioning.In addition, the cross sectional shape of staple fibre can be circular, flat, and is non-circular or hollow.Synthetic staple fibre preferably will have curling, particularly significantly curls.Significantly curl and to form or to form by in spinning process, carrying out uneven cooling by heat treatment to for example parallel type or eccentric core-skin composite fiber such as mechanical means such as crimping machines.
On the other hand, can use polyurethane-type or polyester type elastomer body fiber as binder fiber.Especially preferably use on the composite fibre surface, to expose these elastomeric composite fibres are arranged.In this respect, binder fiber will disperse in certain proportion and be blended in certainly in the precursor fiber above-mentioned and be consistent with the desired performance of final moulded product.
The preferred embodiment of the invention will and be explained in detail with reference to the accompanying drawings below in conjunction with its operation.
Fig. 2 A is a front cross sectional view of realizing the device of the inventive method to 2C, just by the device of scavenger system by the molded buffer element of fibre blend.
In these figure, what reference number 1 was represented is fibre blend; The 2nd, conveyer belt; The 3rd, drive fine instrument; The 4th, air blast; The 5th, carrier pipe.Just fibre blend 1 can be blown under the effect of delivery air among the die cavity C of fibre blend 1 by a kind of like this layout.That is to say that fibre blend 1 supplies on the conveyer belt 2, by after opening fine 3 pairs of fibre blends 1 and disperseing, through carrier pipe 5 and under the following of the delivery air that is produced by air blast 4, further supply among the die cavity C simultaneously.
Die cavity C is by patrix 6, and the inner surface that counterdie 7 and side form 8 surround is defined as.In this respect, patrix 6 and counterdie 7 are by for example perforated plate, and the poromeric materials such as porous plate of wire netting or sintering metal form.Patrix 6 and counterdie 7 can move individually and slide on the internal face of the side form 8 that is formed by the poromeric material that is similar to the former simultaneously.What reference number 9 or 11 was represented is air exhauster; The 10th, air blast; The 12nd, blast pipe; 14 or 15 is a pair of openable dampers that are configured in top or bottom; Wherein, the situation of the air-flow by each contact-making surface (mold wall) W1～W5 can be controlled by these equipment.
Patrix 6 and counterdie 7 are moving on the direction of the fibre blend of extrusion packing in die cavity C (in the embodiment shown in Fig. 2 A～2C for up and down) under the effect of actuating device 16 and 17 respectively independently and/or relatively.In this respect, actuating device 16 or 17 preferably uses oil pressure, the fluid pressure cylinder of hydraulic pressure or air pressure, but also can be traditional electric rectilinear movement device.In brief, actuating device to have can be on the direction of extrusion fiber mixture 1 function of mobile patrix 6 and counterdie 7 be very important.
The contact surface that the invention is characterized in mould 6 and 7 (fibre blend 1 that is filled in the die cavity is wherein arranged) is divided into a plurality of contact-making surface W1～W5, the flow velocity and/or the pressure (dynamic pressure and static pressure) of the air-flow by each contact-making surface are adjusted to predetermined condition, so the air-flow in die cavity C is controlled basically.For this purpose, there is being three contact-making surface W1～W3 that two contact-making surface W4 and W5 are arranged respectively on counterdie 7 and side form 8 simultaneously on the patrix shown in Fig. 26.
In this respect, each contact-making surface W1～W5 is the mold wall that contacts with fibre blend 1.In embodiment as shown in Figure 2, each in counterdie 7 and the side form 8 only has a contact-making surface W4 or W5 respectively.In this mode, can only have a contact-making surface W4 or have a plurality of contact-making surfaces of three contact-making surface W1～W3 as patrix 6 as counterdie 7.In this, form the situation of a plurality of contact-making surfaces and compare, can control performance more subtly, so that make molded condition determine more accurately by the air-flow of contact-making surface with the situation that only forms a contact-making surface.
Therefore, contact-making surface W1～W5 is cut apart like this, promptly will be suitable for moving on the direction of extrusion fiber mixture 1 as one in each mould group (in the embodiment as shown in Figure 2, be W1～W3 in the patrix 6 promptly, be W4 in the counterdie 7)., as in the described embodiment in the back, contact-making surface W1～W5 can move individually.
With reference to the device shown in Fig. 2 A and 2B, the method according to this invention and device will be described below in further detail, be divided into filling process and heat treatment process simultaneously.At first, Fig. 2 A has illustrated a momentary status before fibre blend is blown into die cavity.In this state, the internal area of die cavity C is greater than the state of the molded buffer element 20 shown in Fig. 2 C.The initial cause of increased of the internal area of die cavity C is: can not obtain needed bulk density (packed density) when fully being transformed into buffer element 20 by it is blown into die cavity under the effect of fibre blend 1 at delivery air.In order to obtain needed bulk density, be pressed through the air blowing mode with regard to needs and be filled in fibre blend 1 among the die cavity C.
Secondly, Fig. 2 B has illustrated the facilitation by air blowing mode delivery air in the process that fibre blend 1 is filled, and wherein the controlled direction along arrow of delivery air flows.In the figure, be formed on the damper 14,15th of upper and lower, close.If air exhauster 9 and 11 turns round under this state, delivery air will carry out controlled flow along the direction of arrow so.
In the case, the gas permeability of each the contact-making surface W1～W5 in mould 6～8 can be different to each other respectively.With reference to Fig. 2 A, that is to say, be equivalent to the contact-making surface W1 of die cavity C part and the gas permeability of W3 and be greater than the contact-making surface W2 that is equivalent to die cavity C part, the gas permeability of W4 and W5, wherein, delivery air is difficult to pass W1 and W3 and facilitates penetration of W2, W4 and W5.Therefore, be difficult to enter that fiberfill fibers mixture 1 becomes possibility in the position of die cavity C at fibre blend 1, so just avoided the generation in hole.
In this respect, the gas permeability of mould for example can be opened the quantity in the hole in mould and/or size freely determines by change.
In filling process the effect of delivery air with reference to the accompanying drawings 2B do more detailed description below.
For achieving the above object, reach predetermined condition so that delivery air is mobile along the direction of arrow among Fig. 2 B with regard to flow velocity and/or the pressure (dynamic pressure and static pressure) that must control delivery air.This control can by close shown in Fig. 2 B damper 14 and 15 and the air exhauster 11 that starts under this state upwards discharge delivery air from patrix 6.At this moment keeping up-down adjustment air door 14 and 15 to be in closing state is very important to avoid too much the discharging from contact-making surface W5 of delivery air, wherein side form 8 contacts with fibre blend 1, therefore, all be in order to make fibre blend 1 can be filled into the dark position that limits the die cavity that forms by contact-making surface W1 and W3 fully in the variation of each interface pressure (static pressure and dynamic pressure) and the increase or the reduction of delivery air flow velocity.
When fibre blend 1 is filled in when being limited the dark position of the die cavity that forms by contact-making surface W1 and W3 fully, air exhauster 9 entrys into service relative with the position of carrier pipe 5 (being in open mode), thus fibre blend 1 is by being inserted continuously among the die cavity C by the position of more close air exhauster 9.Be filled into process among the die cavity C so just finished fibre blend.Control delivery air in such a way and reach the state an of the best so that in die cavity C, do not produce the inhomogeneities that fibre blend 1 is filled.
In the described in the above filling process, close that the flow velocity of delivery air and/or pressure (dynamic pressure and static pressure) not only can be by damper 14 and 15 but also adjustment that can be by air exhauster 9 and 11 deflation rate or pressure at expulsion are to control to predetermined condition.In addition, the gas permeability of patrix 6 in contact-making surface W1～W3, gas permeability and the gas permeability of side form 8 in contact-making surface W5 of counterdie 7 in contact-making surface W4 preferably will be adjusted under the corresponding condition in the porosity that changes mould as previously described.
Thereby complete filling is pushed in the mode shown in Fig. 2 C by patrix 6 and counterdie 7 then in the fibre blend among the die cavity C 1 and is obtained buffer element 20 needed bulk densities as mentioned above.In Fig. 2 C, patrix 6 can be on the direction of extrusion fiber mixture 1 moves separately, and certainly, it also is possible finishing extruding by counterdie 7 mobile.
At last, fibre blend 1 is transformed into buffer element 20 by heat treatment.Fig. 2 C has illustrated the facilitation of the molded air-flow of the fibre blend 1 that passes through extruding in heat treatment process.
In this respect, patrix 6 can be made of a plurality of parts that are equivalent to contact-making surface W1～W3, and when extruding is when realizing by moving of patrix 6, each contact-making surface W1～W3 can move down individually.By using this split mould, just can make the different parts of fibre blend 1 have different bulk densities by the degree of compression that changes each contact-making surface.In addition, also must solve the contraction problem in the thermoforming process, because resulting buffer element 20 is because the size that the contraction in heat treatment process can not obtain being scheduled to.For this purpose, the extruding of fibre blend 1 not only can but also can be carried out in heat treatment process or in a plurality of stages afterwards before heat treatment process begins.To make it have excellent size stability be very effective to the extruding heat treatment of this multistage for obtaining buffer element 20.
As mentioned above, fibre blend 1 carries out heat treatment process after being expressed to predetermined bulk density, and it comprises heating steps and cooling step.Heating steps be hot-air is fed in the fibre blend 1 and fused fiber mixture 1 in binder fiber, the binder fiber (it plays a part adhesive) by fusion is adhered to one another the fiber of fibre blend 1.Thereby cooling step is cold air to be fed in the fibre blend 1 and the binder fiber of solidification of molten links together fiber each other securely.Through this two step, fibre blend 1 is transformed into buffer element 20, and this buffer element 20 is by having the formed in mould of precision architecture.
The method according to this invention and device are controlled in heat treatment process and may be accomplished by the molded air-flow of fibre blend 1, wherein molded air-flow role be different from before this effect of the delivery air of narration repeatedly.Certainly in order to realize this control, the free degree of flow regime that is preferred for controlling delivery air and molded air-flow is big as much as possible.Therefore, in order to obtain the sufficient free degree, controlling on crisscross is very easily, and the direction that fibre blend 1 is blown into the delivery air of die cavity C in filling process is generally perpendicular to the direction that molded air-flow is blown into die cavity C in heat treatment process.
Shown in Fig. 2 C, in heat treatment process, comparing with the remainder of the central area that is deposited in die cavity C along the sidewall of side form 8 is that the side surface top fibre blend 1 of die cavity C is piled into bigger height and width smaller in side regions.Therefore, when molded air-flow up/down flows through fibre blend 1, will be owing to making it break away from and be tending towards the central area in the zone from the side having different mistake flow resistance between side regions and the central area, therefore, compare with the part fibre blend 1 that is deposited in the central area, molded air-flow can not be fully by being deposited in that part of fibre blend 1 on the die cavity C side regions.Particularly because molded air-flow can not make that the heat treatment that is present in the fibre blend 1 on the contact-making surface W5 (there, side form 8 contacts with fibre blend 1) is so inabundant by contact-making surface W5.
If molded air-flow can not only be fit to flow through contact-making surface W1～W3 and be suitable for flowing through contact-making surface W5 (side form 8 contacts with fibre blend 1 there), this problem just can be resolved so.That is to say, be provided for controlling the device of molded air-flow velocity so that molded air flow stream is crossed entire contact surface W1～W5.The method according to this invention and device, shown in Fig. 2 C, for realizing this purpose, the damper 14 on top be open and the damper 15 of bottom cuts out.So controlled molded air-flow flows along the direction of arrow shown in Fig. 2 C.In the case, control molded gas by the heat exchanger (not shown) and flow to predetermined temperature, molded air-flow is passed fibre blend 1 from bottom to up by air blast 10.At this moment, since the damper 14 on top be open and the damper 15 of bottom cuts out, so by air exhauster 11, molded air-flow not only can be discharged but also can discharge from contact-making surface W5 (side form 8 contacts with fibre blend 1 there) from contact-making surface W1～W3 (patrix 6 contacts with fibre blend 1 there).
Can use a computer as other device of control air-flow,, the optimum condition of the flow velocity that originally obtains by test be stored in the computer for the flow velocity of controlling the molded air-flow that flows through contact-making surface W1～W5 reaches the value of expection.Based on this, under a preferred situation, the flow velocity of air blast 10 and air exhauster 11 can be through suitable control device converter for example, and the rotary speed of the motor by changing air blast 10 and air exhauster 11 is controlled so that control delivery air and molded air-flow.Air flow controller for example flow control valve or damper can be placed in the blast pipe 12 and the pipeline 13 of air blast in reach the values of expection with the flow velocity of controlling molded air-flow.
In the embodiment above-mentioned, when top damper 14 opens and the damper 15 of bottom when cutting out, the damper 14 on top can cut out, and in contrast, following damper 15 can be that (shown in the dotted line among Fig. 2 C) opened is so that molded air communication is crossed contact-making surface W5 (side form 8 contacts with fibre blend 1 there)., in the case, the direction of the molded air-flow in molded air-flow and the previous embodiments (wherein molded air-flow is discharged from contact-making surface W4) is opposite, and flows to the fibre blend 1 from contact-making surface W4.
According to a further aspect in the invention, mould is divided into a plurality of parts, corresponding to each contact-making surface W1～W5, each contact-making surface all is formed with one and is used to adjust the molded air-flow chamber of (linking to each other with air blowing/blast pipe respectively), so that the flow velocity of air-flow and pressure are controllable and consistent with each air blowing/blast pipe in chamber.Connection can go up/and the carrier pipe of contact-making surface W1～W3 of descending to move must be bellows or the telescoping tube that flexible pipe for example shrinks/stretches.
Take out from side form 8 by moving down actuating device 16 and 17 through the buffer element 20 that the heating and cooling step obtains in such a way, by it being moved up after patrix 6 demouldings, this buffer element 20 is just extracted out from die cavity.
Fig. 3 A and 3B are respectively the sectional side views of mould, and it has illustrated that generally prior art extrusion fiber mixture 1 is to obtain having the method for the buffer element 20 that has vertical wall construction D as shown in Figure 4.
In the method for prior art, the bulk density of controlling fiber mixture 1 is very difficult with the requirement that meets each several part accurately.The long and narrow upright wall part that has that particularly fibre blend 1 is filled in equably as shown in Figure 4 divides that can not lack fibre blend 1 at D place, upright wall part position again among the die cavity C (this zone is by patrix 6, and counterdie 7 and side form 8 surround) of D be to be difficult to.In order to address this problem, mentioned method and apparatus of the present invention above just needing to use.
Method according to prior art, wherein patrix 6 move down last/below the fibre blend 1 that fills up of extruding upwards, even fibre blend 1 can be filled into upright wall part and divide among the D and can not lack fibre blend again, it is still very difficult to desired value to control bulk density on the whole, because upright wall part is very inadequate divided by the extruding of D with respect to other parts.Therefore, as shown in Figure 4, the vertical wall construction D of resulting buffer element 20 after thermoforming is finished is equivalent to the position D (shadow region among the figure) of die cavity C, and it is impossible having predetermined hardness.
In order to solve the defective in the art methods, just need to use apparatus and method of the present invention as shown in Figure 5A and 5B.Identical with the mode among Fig. 2 A～2C, reference number 6 refers to patrix; The 7th, counterdie; 8a～8c is respectively a side form 8, and wherein side form 8 comprises main body 8a, left side element 8b and right side element 8c.Refer to the inlet of blowing by the represented reference number E of two-dot chain line (dotted line).A prerequisite is arranged is that fibre blend has been filled among the die cavity C to Fig. 5 in this, for making the clear profile of having deleted fibre blend of drawing.
The fibre blend of little group by air blast or or following under the effect of other device delivery air that (not shown) produced (the air blowing inlet E that this delivery air is represented through two-dot chain line) insert in the die cavity.
In the embodiment that has illustrated, front or back that the inlet E that blows is formed on side form main body 8a communicate with main body 8a.The position D of die cavity C is widened to a certain degree by the move left and right of left side element 8b and right side element 8c respectively corresponding to the vertical structure D of buffer element 20.
Therefore, with die cavity C in the art methods have shown in Fig. 3 A and 3B to have a long and narrow upright wall part position D opposite, method and apparatus of the present invention can guarantee that delivery air has the path of broad.In addition, shown in Fig. 5 A and 5B, it also is possible that the same wide air blowing inlet of the whole width with a die cavity C E is provided, and different with use irremovable side form on side direction is that this die cavity C can broaden by being displaced sideways of side form.Owing to these reasons, thus the D place, position that delivery air can be introduced die cavity C fully at D place, the position of die cavity C fully the fiberfill fibers mixture can not form the hole again.
When fibre blend was filled among the die cavity C in such a way, fibre blend was squeezed into the shape shown in Fig. 2 A～2C, so that obtain the bulk density of being scheduled in fibre blend.Method and apparatus of the present invention is characterised in that, in extrusion process, the fibre blend of filling not only can last/below upwards push but also can on lateral (front/rear and/or left/right side), push.That is to say that the fibre blend 1 that is filled among the die cavity C can push on bidimensional or three-dimensional.According to said method and device, the bulk density of controlling fiber mixture is possible to predetermined value first on fore-and-aft direction and left and right directions.Promptly, substitute the method for prior art at the fibre blend 1 of extrusion packing on the one dimension direction in die cavity C, according to method of the present invention fibre blend 1 is pushed on bidimensional or three-dimensional direction, then the bulk density of fibre blend real control to desired value.Therefore, even on above-below direction, have among the die cavity C of elongated position D, only by on above-below direction, push basic realization not bulk density can become possibility by increasing lateral compression control.
When the needed hardness/softness in each position of considering buffer element 20, when gas permeability or others, be structure best in the die cavity C-structure in the structure of expanded state lower mode cavity C, at this moment just obtained final buffer element 20.
At last, the details of one of feature of the present invention 6A～6C with reference to the accompanying drawings; Accompanying drawing 8A and 8B and accompanying drawing 9A～9C describe in detail, and the bag shape structure F that at this moment is fit to is formed on the top shown in Figure 1A～1C.In these accompanying drawings, the reference number 10 and 11 in Fig. 6 A～6C is different from the numeral among Fig. 2 A～2C and represents the air blast/air exhauster of molded air-flow, uses identical reference number to represent the same or analogous part with Fig. 2 A～2C.
In Fig. 6 A～6C, die cavity C is by side form 8, and the space boundary that patrix 6 and counterdie 7 surround forms.That is to say that in Fig. 6 A～9C, die cavity C is by the packing space C1 that is used for the fiberfill fibers mixture, C1 ', C2 and C2 ' composition.In this respect, packing space C1 or C1 ', perhaps C2 or C2 ' are formed on and are blown into upwardly extending packing space unit, fibre blend side.
As Fig. 6 A, 7A, shown in 8A and the 9A, below described the invention is characterized in, packing space unit C1, C1 ', C2 and/or C2 ' generally are arranged in perpendicular on the air blowing direction and parallel each other in the mode of multilayer.Usually the present invention is applicable to the buffer element 20 that has top bag shape structure F shown in Figure 1A～1C.In the case, two packing spaces are made up of with C2 or C2 ' C1 or C1 ', and this point front illustrates.With reference to Fig. 5 A and 5B, described these two packing space unit and divide D to be bonded to each other at a pair of upright wall part in the both sides of die cavity C to form a bag shape structure F on the top of buffer element 20.
As Fig. 6 A is illustrated, contacts with fibre blend 1 by mould 6～8 and to limit contact-making surface W1～W4 of forming moving separately or in groups on perpendicular to the direction of blowing.Therefore, the fibre blend 1 that is filled in each packing space unit pushes in order to desirable compression ratio by the work of contact-making surface W1～W4 of moving freely respectively.
In addition, a kind of preferred situation is that the direction shown in the arrow is opposite so that eliminate inhomogeneity in heat treatment process among molded air-flow and Fig. 6 B and the 6C that is blown in the die cavity.This is because only flow in a direction with molded air-flow and to eliminate because the situation of the inhomogeneity that causes of heat treatment is compared, and is filled in fibre blend 1 among the die cavity C and is heated effectively from both sides or cool off.
By being transformed into the flow direction that the state shown in Fig. 6 C switches molded air-flow from state shown in Fig. 6 B, under state shown in Fig. 6 B, molded air-flow has air feeder/air exhauster 10 to produce and discharges from air feeder/air exhauster 11, at state shown in Fig. 6 C, molded air-flow is produced by air feeder/air exhauster 11 and discharges from air feeder/air exhauster 10.In such a way, the molded air communication direction of crossing die cavity C has switched to downward direction shown in Fig. 6 C arrow from the direction that makes progress shown in Fig. 6 B arrow.At this, molded air current flow path upper inlet is opposite basically with outlet in the fibre blend.
Use the method and apparatus shown in Fig. 6 A～6C to come molded buffer element 20 concise and to the point what the present invention that is interpreted as below with labyrinth.In the method for prior art shown in Fig. 7 A and the 7B, when being filled in the fibre blend 1 shown in Fig. 7 A when being expressed to state shown in Fig. 7 B, last/below upwards extrusion packing space cell C1 become packing space unit C1 ' just to become possibility., packing space unit C2 ' obviously can not be extruded.This means can not be in packing space unit C2 ' bulk density of controlling fiber mixture 1 freely.This also means as fruit product complicated structure, for example has bag buffer element of shape structure, just can not obtain high-quality mechanograph, because its bulk density is nonadjustable.
For addressing the above problem, according to the first embodiment of the present invention, fibre blend 1 preferably is filled among the packing space unit C1 shown in Fig. 8 A.It is very important that the air blowing inlet E of fibre blend 1 must be positioned at the position that can optionally fibre blend 1 be supplied to packing space unit C1.This is to be possible because be filled into fibre blend 1 in each packing space unit following under the effect of delivery air by the inlet E that blows.It should be noted that in this respect the packing space unit C2 ' among Fig. 8 A still can not be supplied with fibre blend 1 at this moment.
As mentioned above, at packing space unit C1 after complete filling has had fibre blend 1, thereby patrix 6a moves down mobile contact-making surface W3 or W4 on the direction of extrusion fiber mixture 1 shown in Fig. 8 B.So packing space unit C1 is compressed into the packing space unit C1 ' shown in Fig. 8 B.Only consider under the situation of packing space unit C1 that not considering packing space unit C2 ' bulk density that control is seated in the fibre blend 1 in the packing space unit C1 is possible to desired value.Certainly, compression ratio should reasonably be selected according to the desirable performance of end article.
And then, shown in Fig. 8 B, along with moving of patrix 6a, the inlet E that blows is positioned at the center of the packing space unit C2 that broadens automatically.So filling mixture 1 just becomes possibility in packing space unit C2.At that time, packing space unit C1 ' is disconnected with just the getting in touch of E of inlet of blowing.As a result, fibre blend 1 just can not be fed in the packing space unit C1 '.And packing space unit C2 occurs with moving of patrix 6a, and this packing space unit C2 has one to be used to regulate the volume of the bulk density of fibre blend 1 to desired value.At this moment it is very important carefully the mobile of patrix 6b not taken place, otherwise contact-making surface W1 will move.Fibre blend 1 supplies to the packing space unit C2 that forms under this state and fills up this packing space unit C2 from the inlet E that blows.
Afterwards, shown in Fig. 8 C, mobile patrix 6b is squeezed into C2 ' so that the bulk density of the fibre blend 1 in the C2 ' of space controls to the value of expectation with packing space unit C2.Under this state, fibre blend 1 is thermally molded into has bag buffer element of shape structure 20.
Except method above-mentioned, can realize fibre blend 1 is filled in the packing space unit by the method shown in Fig. 9 A～9C, this method will describe in detail below.
In Fig. 9 A, a plurality of air blowing inlet E1 of formation are corresponding with packing space unit C1 and C2 respectively with E2, and this point is to be different from the system shown in Fig. 8 A～8C.Owing to adopt this structure in this embodiment, its benefit is: fibre blend 1 can supply to a plurality of packing spaces unit C1 and C2 simultaneously.
In Fig. 9 B, side form 8 moves on perpendicular to the direction of arrow of the direction that is blown into fibre blend 1 so that the inlet E that blows can face each among packing space unit C1 and the C2.Therefore, load each packing space unit C1 continuously by the inlet E that blows and C2 is possible.
In Fig. 9 C, according to the commutation campaign of deflecting plates 18 on the direction of arrow, by changing the air blowing direction of the inlet E that blows, fibre blend 1 is just inserted packing space unit C1 and C2 continuously at last.
According to the present invention described above, change like a cork through the air-flow of over-segmentation contact-making surface and do in order to suitable filling process and heat treatment process are possible respectively.Wherein, in filling process, fibre blend is carried by delivery air, and in heat treatment process, just need be by molded air-flow fast, carry out heat exchange with fibre blend equably.The contact-making surface of cutting apart moves on the direction of extrusion fiber mixture, therefore for example not have the inhomogeneity generation of filling and can shorten the molded time in the buffer element of bag shape structure having complicated three-dimensional structure.Also heat treated inhomogeneities can not take place even shortened the molded time, so just can obtain buffer element by industrial production, it is in mass-producted productivity ratio, and it all is very outstanding saving on cost and the product quality.
Claims (12)
1. method by the molded buffer element of fibre blend (1) (20) is used a kind of air-permeable mold with the contact surface of fibre blend that has, and wherein contact surface is divided into a plurality of contact-making surfaces (W1-W5), and this method may further comprise the steps:
To insert in the die cavity (C) of air-permeable mold by the effect of the delivery air that passes through contact-making surface of filling usefulness by the opening fiber mixture (1) that synthetic precursor fiber and binder fiber are formed,
The fibre blend (1) in the die cavity (C) is inserted in compression,
A heat treatment step comprises making molded air communication cross contact-making surface (W1-W5), so that the heating fibre blend is used for bond vitrified agent fiber and follows the fibre blend of cooling through heating, makes the binding agent of fibre blend and fusion integrated,
It is characterized in that, carry and fill the flow velocity of air-flow and/or pressure by contact-making surface (W1-W5) control, the flow velocity and/or the pressure of the air-flow by each contact-making surface divide other control in filling process and heat treatment process.
2. according to the method for claim 1 by the molded buffer element of fibre blend (1) (20), it is characterized in that, cross that air-breathing and exhaust (9,11) is controlled so that the flow velocity and/or the pressure of the air-flow by contact-making surface (W1-W5) meet predetermined condition by the air communication of contact-making surface (W1-W5).
3. according to claim 1 or 2 methods by the molded buffer element of fibre blend (1) (20), it is characterized in that, delivery air in filling process, control in case the air-flow velocity of that part of die cavity (C) contact-making surface that is difficult to be filled into by fibre blend (1) will be optionally greater than the flow velocity of other contact-making surface.
4. according to claim 1 or 2 methods, it is characterized in that the flow velocity of molded air-flow is controlled so that molded air-flow passes through whole contact-making surfaces (W1-W5) basically in heat treatment process by the molded buffer element of fibre blend (1) (20).
5. according to the method for claim 1 by the molded buffer element of fibre blend (1) (20), it is characterized in that, in filling process, be used for fibre blend is supplied to the direction of delivery air of die cavity (C) usually perpendicular to the direction of the molded air-flow that is blown into die cavity in heat treatment process.
6. according to claim 1 or 5 methods, it is characterized in that the direction that is blown into the molded air-flow in the die cavity (C) is opposite in heat treatment process by the molded buffer element of fibre blend (1) (20).
7. according to the method for claim 1 by the molded buffer element of fibre blend (1) (20), it is characterized in that, be arranged on contact-making surface on the fibre blend side that fills in the die cavity on lateral, move with from the fibre blend of side extrusion packing so that the bulk density that makes fibre blend obtain being scheduled to.
8. according to claim 1 or 7 methods, it is characterized in that a plurality of packing spaces unit is arranged in parallel with each other in the mode of multilayer and forms die cavity (C) by the molded buffer element of fibre blend (1) (20); But packing space unit fiberfill fibers mixture (1) also can extend on the direction of delivery of fibers mixture; Wherein general the moving on perpendicular to the direction that fibre blend is supplied to die cavity of contact-making surface (W1-W5) can be controlled separately so that be filled in the bulk density of the fibre blend in each packing space unit.
9. device by the molded buffer element of fibre blend (1), this fibre blend is made up of synthetic precursor fiber and the binder fiber that is dispersed in wherein, and this device comprises:
Hot-air generator;
Have an air-permeable mold with the contact surface of fibre blend (1), described contact surface is divided into a plurality of contact-making surfaces (W1-W5);
Carrier pipe (5) is used for the fibre blend of shredding state is transported to die cavity;
Actuating device (16,17) is used for moving moulds and inserts the fibre blend of die cavity with compression;
Hair-dryer (10) and/or exhaust blower (9,11) are used for air-flow is blown into die cavity and/or therefrom discharges air-flow;
It is characterized in that, the flow velocity of the air by each contact-making surface (W1-W5) and/or pressure can fill and heat treatment process in control respectively; With
This device comprises also that a control device is used for controlling respectively and fills and flow velocity and/or the pressure of heat treatment process by the air-flow of each contact-making surface (W1-W5) arrives predetermined condition.
10. according to the device of claim 9 by the molded buffer element of fibre blend (1) (20), it is characterized in that the direction that is used for fibre blend (1) is supplied to the delivery air of die cavity (C) in filling process is generally perpendicular to the direction that is blown into the molded air-flow of die cavity in heat treatment process.
11., it is characterized in that contact-making surface (W1-W5) can be separately on the direction of extrusion fiber mixture or moving in groups according to claim 9 or 10 devices by the molded buffer element of fibre blend.
12., it is characterized in that each removable contact-making surface (W1-W5) can be independent in the one dimension direction according to the device of claim 11 by the molded buffer element of fibre blend, on/following direction, a front/rear direction or a left side/right-hand moving up.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN98127127A CN1119237C (en) | 1998-12-28 | 1998-12-28 | Method and apparatus for moulding fibre mixture |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN98127127A CN1119237C (en) | 1998-12-28 | 1998-12-28 | Method and apparatus for moulding fibre mixture |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1258598A CN1258598A (en) | 2000-07-05 |
| CN1119237C true CN1119237C (en) | 2003-08-27 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN98127127A Expired - Fee Related CN1119237C (en) | 1998-12-28 | 1998-12-28 | Method and apparatus for moulding fibre mixture |
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| Country | Link |
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| CN (1) | CN1119237C (en) |
Families Citing this family (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4376439B2 (en) * | 2000-09-27 | 2009-12-02 | トヨタ紡織株式会社 | FIBER LAYER, ITS MANUFACTURING METHOD, AND ITS MANUFACTURING DEVICE |
| JP4194880B2 (en) * | 2003-05-20 | 2008-12-10 | トヨタ紡織株式会社 | Fiber molded body and method for producing the same |
| US7931845B2 (en) * | 2007-05-21 | 2011-04-26 | O & D Manufacturing | Gravity injection of molding material for compression molding and related methods |
| EP2532777A1 (en) * | 2011-05-19 | 2012-12-12 | Autoneum Management AG | Device for moulding fibrous material |
| CN102583211B (en) * | 2012-01-15 | 2015-07-01 | 河北杰力伟机械设备有限公司 | Novel dust-collection cotton fluffer |
| CN102776719B (en) * | 2012-07-11 | 2014-04-16 | 常熟市飞龙无纺机械有限公司 | Preforming box structure for automotive interior preforming machine through air filling method |
| CN103522579B (en) * | 2013-10-10 | 2015-05-20 | 泉州三嘉机械有限公司 | Forming machine for vacuum insulated panel |
| CN104964869A (en) * | 2015-07-01 | 2015-10-07 | 中山出入境检验检疫局检验检疫技术中心 | Mixing method and equipment of semifinished standard fiber-component-content products |
| CN109483900A (en) * | 2018-09-11 | 2019-03-19 | 上海新安汽车隔音毡有限公司 | A kind of production method of automobile PET superfine fibre part |
| CN110152904A (en) * | 2019-06-12 | 2019-08-23 | 薛德刚 | A kind of system and device and method spraying aeroge, fiber and binder mixture |
| CN111455560B (en) * | 2020-04-27 | 2022-07-05 | 邵庆河 | Intelligent panty-shape diapers cotton fibre processing equipment |
| CN111648026B (en) * | 2020-05-23 | 2022-08-23 | 保定棉金汽车饰件制造有限公司 | Cotton cushion block shaping die and production equipment |
| CN113293527B (en) * | 2021-07-28 | 2021-09-21 | 南通辰展纺织有限公司 | Fabric filling machine and filling process |
| CN116945444A (en) * | 2023-07-18 | 2023-10-27 | 肥城三合工程材料有限公司 | Preparation process of basalt fiber reinforced PVC composite material |
-
1998
- 1998-12-28 CN CN98127127A patent/CN1119237C/en not_active Expired - Fee Related
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| CN1258598A (en) | 2000-07-05 |
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