DE102011000838A1 - Device for producing a dimensionally stable molded article and method for producing such shaped articles - Google Patents

Abstract

The invention relates to a device for producing a dimensionally stable molded body. It also relates to the manufacturing process for the dimensionally stable molded body. According to the invention, accompanying substances are placed on a blank of a flat structure, this arrangement is deformed into a die and shaped with a winding process to form an essentially rotationally symmetrical, dimensionally stable molded body, which is later able to release the added accompanying substances in a metered manner in application processes.

Description

The invention relates to a device for producing a dimensionally stable molded article. In particular, it relates to a device for producing a dimensionally stable wound shaped body which has cavities in the interior and to which accompanying substances can be added before or during the winding process. Furthermore, the invention relates to a production method for the dimensionally stable shaped body.

There are known devices that produce moldings by winding. These process a sheet of natural fibers, which is fed during the winding process, an aqueous binder. Such kind of winding body are wound mainly from pulp slit strip, added during the winding process dextrin, cellulose or starch adhesive and finally dried the moldings.

The moldings produced in this way are wound in their entire volume with substantially constant density and have virtually no voids in the interior. If such wound bodies are added with additional substances during the winding process, these are, above all, dyes or substances with different active spectra which are introduced into the winding body via the wet phase.

The wound bodies thus produced and impregnated must be fed to a drying process after the winding process.

The winding bodies described above are not wet-strength. In addition, they are not suitable to absorb additives that are present in solid, pasty or a mixed form thereof, if only one additive is water-soluble.

Furthermore, the bobbins described above have no cavities inside, which is why they are practically unsuitable for addition of non-liquid additives. Such additions also do not allow the winding devices used.

There is a need for molded articles which can be produced by a winding process using fiber-fabricated fabrics, have cavities for receiving additives inside them and which can serve to distribute the additives contained in an application process. In this case, there is a main requirement that the bobbins can release the contained additives metered. Another requirement is that the sheet must not dissolve in said application process.

From this need and the resulting technical specifications for such moldings, a need arises for facilities that can produce these moldings. In particular, there is a need for facilities that can produce the moldings in one step as possible finished.

It is therefore an object of the invention to provide a device which makes it possible to produce bobbins with the properties described above, especially with cavities located in the interior, wherein the device at the same time must introduce the accompanying substances in the generation of the winding body in this. It is a further object of the invention to propose a manufacturing method for the winding body produced with the device.

The object is achieved by a device having the features of the characterizing part of one of the claims 1 or 2 in conjunction with the features of the preambles of these claims. The object is further achieved by a manufacturing method according to the features of the characterizing part of claim 9 in conjunction with the features of the preamble of this claim. Secondary and subordinate claims describe other embodiments of the device or method of manufacture. They do not limit the scope of the invention.

In the following description, embodiments and claims, the following terms are used with the following meaning:

Shaped body - is a three-dimensional body produced from a fabric with a plurality of winding layers, wherein cavities for receiving additives are present between individual winding layers.

Sheet - is a fabric formed by interconnecting fibers and / or filaments having a moisture resistant bond.

Cutting - is a geometrically defined section of the fabric.

Cavity - is a space between two layers of a winding with a size and shape which can not be determined beforehand during the winding process and which can absorb additives.

Additives - are substances, especially in solid, especially in granular, free-flowing, powdery, pasty or a mixed form in the finished body in its cavities are arranged and released dosed in a later case of use by the molding.

According to the invention, a blank of a sheet is fed to a die of the shape that is arranged approximately in the middle of the blank over the die and the blank protrudes on all sides beyond the die.

It can be provided during the feeding of the blank to the die to spray it with a liquid.

Subsequently, the center of the blank is pressed into the die using a mandrel. Before, during or after pressing into the die, an additive or a mixture of several additives is added to the blank or into the already existing recess of the blank. The filling process can be maintained over a time interval.

After filling, the die is pushed down to an end position by the mandrel. The annular central part of the die is fixed in a winding position. The annular central part has a horizontal hole through which a linearly displaceable winding mandrel penetrates into the already prefolded shaped body, in doing so comes into contact with fibers or threads of the blank and wound up the entire blank. The middle part of the die forms the template for the winding of the molding. After completion of the winding process, the winding mandrel is withdrawn and the wound molded body removed from the central part of the die.

In another embodiment of the die is the same divided, with a Gesenkboden is additionally arranged, which can be moved by vertical displacement to an end position down, while the annular central part of the die is fixed in a winding position.

In one embodiment of the invention, the removal can take place by means of the mandrel which has been lowered again in a subsequent shaping operation, wherein the mandrel can be pushed out of the die with the prefolded next shaped body.

A further embodiment of the invention may consist in that the mandrel at the end of the winding process ejects the shaped body by a vertical movement.

Likewise, ejection of the molded body by additional mechanical components (plunger), by compressed air or by negative pressure.

A further embodiment of the invention is that immediately before the ejection process, a container is positioned under the middle part of the die and the ejected molded body is collected by this and optionally transported away.

It can be provided for further transport to a dwell position. It is also possible to supply the ejected molded body directly to a container.

If a dwell position is provided, then this serves to allow at least some bonding of the binder applied to the blank during the winding process, before further transport or aftertreatment or packaging follows the shaped body.

Another embodiment of the device dispenses with a separate winding mandrel. Following or simultaneously with the filling, the die together with the blank rotates and the blank undergoes folds as a result of friction on non-rotating components, is twisted and finally forms a winding. The finished in this way winding body is closed on all sides and has a substantially rotationally symmetrical spatial form.

The above-described means for feeding the blank, for its deformation in the die, for the supply of the accompanying substances and for a possible spraying of the blank remain largely unchanged. Likewise, the various possibilities of removal of the ejected molding.

It has been found that the processing of the blanks by winding is substantially facilitated if the blanks have been wetted with liquid prior to winding.

In this case, in addition to water, especially a binder solution in question.

Wetting with water can also serve to dissolve a binder already applied to the blanks and to activate in this way.

The type of binder and the method of addition are largely variable.

The manufacturing method practiced with the above-described device is such that a blank is first fed to the device. This can be removed from a storage tank.

Another method embodiment provides before the first step, the supply of a sheet in the form of a slit strip, which is cut to length by means of a cutting process.

During feeding, in an optional operation, the blank of the fabric may be wetted with a liquid.

The supplied blank is then aligned over a die so that it projects beyond the die on all sides.

In this position, an accompanying substance or a mixture of accompanying substances can be added in a further working step, whereby the blank can already sink somewhat into the die.

By a vertically displaceable mandrel, the blank is then pressed into the die, wherein the blank undergoes a random folding. In this working position, further addition of accompanying substances can take place. This is possible either via a feed channel contained in the mandrel or after pulling the mandrel.

In the work step, which follows the pulling of the mandrel, a motor-driven mandrel is moved laterally into the die by means of a feed unit. The winding mandrel rotating during retraction captures individual fibers or threads of the blank, twisting them and as the winding process progresses, an approximately spherical filler body which is closed on all sides forms.

Finally, the resulting molded body is ejected, for which purpose the die can be opened at the bottom. In the space between the die and die lower part, a means can be retracted, which takes over and requests the ejected molding.

Alternatively, a dwell position can be approached after removal.

In the dwell position, a heat can be supplied.

Again alternatively, the resulting molding can be ejected by the vertically displaceable mandrel, by compressed air from the die or sucked out of it by negative pressure.

The operations described above can be repeated in a new cycle.

If the die is completed by a bottom part, it is first closed again prior to the execution of a new work cycle.

An embodiment of the invention provides to cover the top open die by an additional aperture. The panel consists of an elastic material and is deformed so far when lowering the vertically displaceable mandrel that the blank is pushed along with all the accompanying substances.

Another embodiment of the method described above provides that the die rotates as such during the winding process of the shaped body about its vertical axis The top of the die closing elastic diaphragm holds it parts of the blank initially fixed, whereby the blank is twisted and the molding is closed.

The invention will be explained in more detail below with reference to some embodiments and drawings. Showing:

1 - The main parts of the device according to the invention with an already supplied blank, which is positioned over the die and filled with accompanying material.

2 - The same device in a state in which the vertically displaceable mandrel has pressed the blank in the die and the vertically displaceable mandrel is still lowered.

3 - The device during the winding process, wherein the driven mandrel is retracted into the die.

4 - The device, wherein the wound molded body is ejected by the lowered vertically displaceable mandrel from the open die down.

5 - A form of the device in which the die itself performs a rotational movement.

On a plate 1 that a breakthrough 2 has, is a blank 3 from a feeder, the 1 not shown, provided. The cut 3 is over the breakthrough 2 positioned so that it covers all sides.

When feeding the blank 3 is from a spraying device 4 a liquid has been applied to the blank 3 makes it more supple. Alternatively, depending on the material of the blank 3 wetting with water, an organic liquid, an adhesive dispersion, an in-line activator already contained substance components or a glue coat are applied.

Under the plate 1 There is a die made of an annular component 5 and a bottom part 6 consists.

The die can also without the bottom part 6 be executed. In this case, only the annular component forms 5 the die.

Concentric over the die is a vertically displaceable mandrel 7 arranged A feeder 8th , in the 1 exemplified as a gutter, leads approximately in the center of the Gesengks accompanying materials 9 too, resulting in the blank 3 a collection 10 the accompanying substances deposits. The device also has an aperture in the plate 11 made of an elastic material, which partially closes the opening of the die. The device is also a winding device consisting of a winding mandrel 12 , a drive motor 13 and a displacement unit 14 , assigned. The annular component 5 has a radial bore 15 , in the winding mandrel 12 can be introduced.

After filling the blank 3 with accompanying substances 9 becomes the vertically displaceable mandrel 7 pressed into the die, with the elastic panel 11 preforming into the die and the cutting with the deposited accompanying substances 9 receives a bag-like recessed and folded intermediate form.

The following is the vertically displaceable mandrel 7 pulled back from the die and then moved the winding device so far to the die, that the winding mandrel 12 through the radial bore 15 in the interior 16 einfährt the die, there recorded fibers of the blank, this twisted and by the cohesion of the blank this ultimately to a closed winding 17 winds. After completion of the winding process, the winding device is moved back to its original position, wherein the mandrel from the die and from the radial bore 15 is pulled.

By lowering the vertically displaceable mandrel again 7 and simultaneously opening the bottom part 6 can the resulting shaped body 18 be removed down from the die. For storing and transporting is a catch tray 19 provided before the ejection of the shaped body 18 is driven under the die.

After removing the catcher 19 with the molding 18 The die can be closed again and the vertically movable mandrel 7 be returned to the starting position. The process described can begin again for the production of a further shaped body.

The cut 3 is a fabric with a self-released bond between the fibers, which only has to withstand the breaking forces occurring during the winding process. The cut 3 Therefore, it can consist of both a nonwoven, an additionally mechanically bonded nonwoven, a nonwoven with adhesive bonding of the fibers, a woven fabric, a knitted fabric or the like. Other requirements for the blank may be that it must be wet or waterproof during later use, that it must be resistant to certain chemical substances or the like.

It may be necessary to add a binder (adhesive) during winding of the molded article in addition to the resulting mechanical bonds of the fibers. The requirements for such binders in turn result from the required property profiles in the use of the moldings and from the chemical-physical properties of the introduced accompanying substances.

The impurities may be granular, free-flowing, flowing, powdery, pasty or a mixture of components having these properties in terms of their nature.

With regard to their physicochemical properties, the accompanying substances must 9 be suitable to be wrapped in the inventive device in a shaped body.

Another embodiment of the device according to the invention provides that the die 20 consisting of an annular component 21 and the Gesenkboden 22 , can rotate itself. After folding the blank 3 in the die and pulling the vertically movable mandrel 7 The elastic panel partially closes and shapes the blank into a bag. Upon insertion of the rotary motion of the die, the folded top becomes 23 of the blank 3 twisted and closed the molding.

Feeding and discharging from the die may be performed as described in the first embodiment.

The device according to the invention can be supplemented by additional means. Thus, via conveying elements of the ejected molded body 18 transported directly into a waiting container. It is also possible, the molding 18 in a residence position, where it can be optionally heated and, for example, during its production in the molding 18 introduced fluids are expelled again.

The supply of blanks 3 may be configured so that they are shared immediately prior to feeding the blanks, while otherwise a belt is fed via a feed apparatus.

If the moldings permit, conveyors can also be used for direct packaging or for additional wrapping with packaging materials, such as films.

The inventive method provides that in a first step, a blank 3 fed and the same is positioned over a die.

When feeding, an additional operation may be carried out, in which a liquid via a spray device 4 on the surface of the blank 3 is applied.

Subsequently, on the blank is a subset of an accompanying material 9 deposited so that it is located approximately above the die.

Subsequently, a vertically displaceable mandrel enters the die and takes the blank and the deposited amount of accompanying substances 9 with in the die interior 16 , wherein the blank 3 is prefolded to a bag.

Subsequently, the vertically displaceable mandrel 7 pulled and a winding device moves with its winding mandrel 12 in the die, the winding mandrel 12 Fibers of the blank 3 captured, twisted and ultimately wound up the entire blank, with the deposition of the accompanying substances 9 is included in the resulting molded body.

After completion of the roll 17 the winding mandrel is pulled by moving back the winding device.

Subsequently, the die by lowering the bottom part 6 opened, the vertically movable mandrel 7 goes into the Gesenk and pushes the winding 17 out of the die. After being released the shaped body takes 18 its final form.

Subsequently, the shaped body 18 promoted out of the institution.

Another form of the manufacturing method provides that instead of winding with a winding mandrel, the die rotates as a whole and the shaped body in this manner by twisting the protruding ends of the blank 3 is wound.

The invention thus has the advantage that it allows to produce by winding substantially rotationally symmetrical shaped body, which can be filled with impurities, permanently enclose them after completion and at the same time open the possibility of dosing the accompanying substances in the following uses of the molding release and, if necessary, in a wet phase also dissolve the bobbin again.

LIST OF REFERENCE NUMBERS

1

plate

2

breakthrough

3

cut

4

sprayer

5

Annular component

6

the bottom part

7

Vertically displaceable mandrel

8th

feeding

9

accompanying substances

10

Accumulation of accompanying substances 9 ]

11

cover

12

mandrel

13

drive motor

14

displacement unit

15

Radial bore

16

Interior of the die

17

reel

18

moldings

19

catcher

20

die

21

Annular component

22

Gesenkboden

23

Folded top of the blank [ 3 ]

Claims (14)

Device for producing a dimensionally stable shaped article ( 18 ), which consists of a wrap ( 17 ) and in the interior of the same distributed arranged accompanying substances ( 9 ), characterized in that the device comprises: - means for feeding blanks ( 3 ) of a sheet, the means comprising the blank ( 3 ) at the same time positioned above a die so that its edges protrude beyond the edge of the die, - the die at least from an annular component ( 5 ), - over the die vertically displaceable a mandrel ( 7 ) is arranged, which can at least partially enter with its lower end in the die and whose lower end is adapted to the shape of the die approximately, - a feeder ( 8th ) is arranged so that it contains accompanying substances ( 9 ) on the blank ( 3 ) of Can position sheet material or in a hopper prefilled by lowering the cylindrical component, - a spraying device ( 4 ), which transfers a binder to the fabric, - wherein the vertically displaceable mandrel ( 7 ) after feeding and aligning the blank ( 3 ) of the fabric with the same in the die is retractable, in about the same time accompanying substances ( 9 ) can be added and in a lateral bore of the annular member ( 5 ) of the die a winding mandrel ( 12 ), whereby - by interaction between the blank ( 3 ), the mandrel ( 12 ) and the annular component ( 5 ) a shaped body ( 18 ) which is closed and removable from the die. Device for producing a dimensionally stable shaped article ( 18 ), which consists of a wrap ( 17 ) and in the interior of the same distributed arranged accompanying substances ( 9 ), characterized in that the device comprises: - means for feeding blanks ( 3 ) of a sheet, the means comprising the blank ( 3 ) at the same time positioned above a die so that its edges protrude beyond the edge of the die, - the die is multi-part and at least from a bottom part ( 6 ) and an annular component ( 5 ) and is lowerable, - above the die vertically displaceable a mandrel ( 7 ) is arranged, which can at least partially enter with its lower end in the die and whose lower end is adapted to the shape of the die approximately, - a feeder ( 8th ) is arranged so that it contains accompanying substances ( 9 ) on the blank ( 3 ) of the sheet or in a pre-folded by lowering the cylindrical member hopper, - a spraying device ( 4 ), which transfers a binder to the fabric, - wherein the vertically displaceable mandrel ( 7 ) after feeding and aligning the blank ( 3 ) of the fabric with the same in the die is retractable, at the same time accompanying substances ( 9 ), wherein the die can perform a rotational movement and the blank ( 3 ) can be carried by frictional engagement with the die and at the same time portions of the blank ( 3 ) can be braked by rigid components and thereby a winding process is executable that the molded body ( 18 ) can produce in the die, can close the same and is removable after the closing operation of the die. Device according to claim 1, characterized in that the blank ( 3 ) of the fabric can be removed from a storage store of finished blanks or can be fed by a feed unit in strip or strip form and produced by a cutting device assigned to it, wherein this can be conveyed and aligned by a conveyor to the die. Device according to claim 1, characterized in that the blank ( 3 ) before or during transport to the die by means of a spraying device ( 4 ) is wettable with a liquid. Device according to claim 1, characterized in that the vertically displaceable mandrel ( 7 ) a feed channel for the accompanying substances ( 9 ) Has. Device according to claim 1, characterized in that it has a dwell position or a dwell area into which the shaped body ( 18 ) remains until the binder solidifies. Device according to claim 6, characterized in that in the dwell position or the dwell a supply of heat is provided. Device according to claim 1, characterized in that the die or the dwell position a Fordereinrichtung for removing the moldings ( 18 ) assigned. Process for the production of a molded article with a device according to one of claims 1 to 8, characterized in that a blank ( 3 ) is fed to the device and positioned via a die so that the blank ( 3 ) on each side of the die beyond the opening thereof subsequently survives a variable amount of impurities ( 9 ) approximately to the center of the blank ( 3 ), then or simultaneously a vertically displaceable mandrel ( 7 ) the center of the blank ( 3 ) pushes into the die and then moves back to the starting position, the blank ( 3 ) is rotated by a winding device in a rotational movement and is formed into a closed winding, below the shaped body ( 18 ) is removed down from the die. Method according to claim 9, characterized in that the blank ( 3 ) is wetted with a liquid prior to positioning over the die. Method according to one of claims 9 or 10, characterized in that the blank ( 3 ) is separated by a cutting device of a slit strip. Method according to one of claims 9 to 11, characterized in that a winding mandrel enters the side of the die and by interaction with the blank ( 3 ) a wrap ( 17 ) produced in the die. Method according to one of claims 9 to 12, characterized in that the winding ( 17 ) by rotation of the die, consisting of annular component ( 5 ) and bottom part ( 6 ) is generated in interaction with fixed components of the device. Method according to one of claims 9 to 13, characterized in that the shaped body ( 18 ) after being demolded by a conveyor or a collecting tray ( 19 ) is taken over.

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