JP2004209831A - Resin roll manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin roll manufacturing apparatus for continuously manufacturing a resin roll almost the same in physical properties by reacting and curing a flowable resin raw material while transferring the same using a long sheet for regulating the outer shape of the resin roll using a molding pipe of which the inner diameter is almost equal to the outer diameter of the resin roll to be obtained. <P>SOLUTION: The resin roll manufacturing apparatus is constituted of the molding pipe 20 of which the inner diameter is almost equal to the outer diameter of the resin roll R to be obtained, a long sheet supply device 24 arranged on the upstream side of the molding pipe, a cylinder manufacturing device 30 for molding a first long sheet 92 into a long cylindrical body 93 on the downstream side of the device 24, a raw material supply device 50 for supplying the flowable resin raw material M in the molding process of the device 30, a heating device 60 for reacting and curing the raw material M in a surrounded state and a long roll product pulling device 70 arranged on the most downstream side and pulling an obtained long resin roll product LR to transfer the same. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an apparatus for manufacturing a resin roll, and more specifically, for example, from a flowable resin material containing air bubbles adjusted by a mechanical floss (mechanical stirring) method or the like, at least in an axial direction (longitudinal direction), The present invention relates to a manufacturing apparatus for continuously manufacturing resin rolls capable of eliminating differences in physical properties such as hardness in a radial direction and making them substantially the same.
[0002]
[Prior art]
2. Description of the Related Art Components such as a transfer roll and a paper feeding / feeding roll are provided in a copying machine, a fax, and other office equipment. This roll is obtained by forming a high-performance urethane material having a so-called microcell structure as a roll of a required length, and coaxially inserting and arranging a shaft as a rotation support member. Then, when forming into the roll, generally, without adding water or a foaming material to the raw material, dry air or an inert foaming gas such as nitrogen is mixed to produce a required foam. A mechanical stirring method (hereinafter, referred to as a mechanical floss method) is suitably employed. The roll obtained by employing the mechanical floss method has structural features such that the size of bubbles contained therein is substantially the same and uniformly dispersed, and that the shape has small anisotropy. For this reason, the roll obtained can be supplied without slipping because the pressing force on the outer peripheral surface, that is, the nip pressure (nip amount) required when feeding a sheet-like conveyed object such as printing paper is constant. It has excellent advantages such as the ability to send.
[0003]
In order to contribute to the understanding of the prior art, an example of a method for manufacturing a resin roll made of a urethane foam by a mechanical floss method and an example of an apparatus therefor will be described below. The roll obtained here is a flowable gas-mixed raw material obtained by mixing the foaming gas and the raw material (hereinafter, referred to as a flowable resin raw material (here, a urethane foam resin)) M Is molded into a mold 216 having a cavity 218 that matches the shape of the product to be obtained, for example, as shown in FIGS. The molding die 216 rotatably supports a pair of mold halves 222 in which a plurality of cavity halves 220 defining a plurality of independent cavities 218 are recessed in parallel on the contact surface. In this case, the plurality of molds 216 are arranged in parallel along the transport line. An injection hole 224 for injecting the fluid resin material M is provided at a predetermined position of the molding die 216 so as to be in spatial communication with the cavity 218. Further, each of the cavity halves 220 has a semicircular cross-section groove extending from a position extending from both end portions of the foamed resin roll R, which is a molded product to be obtained, to each end portion of the mold half 222. 226 is formed, and the core 228 is mounted through the groove 226 when the mold 216 is opened.
[0004]
When manufacturing the resin roll R, the molding die 216 is used as follows (see FIG. 21). That is,
{Circle around (1)} One of the mold halves 222 of the molding die 216 arriving from the upstream side to the core mounting position 230 arranged at a predetermined position in the production line of the resin roll R is rotated, and the cavity half 220 is rotated. Release.
(2) In this state, the cores 228 are mounted on the respective cavity halves 220 of the one mold half 222 via the grooves 226. The core 228 itself is set to have the same outer diameter as the shaft concentrically inserted and disposed in the final product, the resin roll R, and has a dimension sufficiently longer than the axial length of the roll R. When the rod-shaped member is set in the groove 226, a sufficient space for molding, that is, a cavity 218 is defined between the half-body 220 and the inner surface thereof in alignment with the axis of the cavity half 220. To achieve.
[0005]
{Circle around (3)} The molding die 216 on which the core 228 is mounted is closed by rotating one of the mold halves 222, and for example, the raw material on the downstream side along the production line by one block. It is moved to the injection device 232. As a result, another mold 216 that has been located on the upstream side is conveyed to the downstream side, and when it reaches the core mounting position 230, one of the mold halves as with the former mold 216. The body 222 is opened, and the cores 228 are attached to the respective cavities 218. Then, by repeating this procedure, the mold 216 on which the core 228 is mounted is sequentially transferred to the downstream side along the production line.
{Circle around (4)} The fluid resin material M is injected into the molding die 216 conveyed downstream of the production line via the injection hole 224.
(5) The molding die 216 into which the fluid resin material M has been injected is heated by a tunnel heating furnace 234 provided further downstream of the production line. As a result, the fluid resin material M reacts and hardens in the cavity 218, and is formed into a roll having an internal contour of the cavity 218 as an external contour. The tunnel heating furnace 234 is a heating furnace of a required length formed along a production line, and its internal temperature is controlled and maintained at a required temperature required for reaction and curing of the fluid resin material M. .
[0006]
{Circle around (6)} After the completion of the reaction and curing by heating in the tunnel heating furnace 234, the molding die 216 is transported to a demolding station 236 located further downstream. At the demolding station 236, the molding die 216 is opened by the rotation of one of the mold halves 222. In this state, by removing both ends of the core 228 from the groove 226, the resin roll R of the foam, which is a molded product, is separated from the cavity half 220, and the core 228 is further removed from the roll R. A molded article is obtained by drawing.
[0007]
[Problems to be solved by the invention]
By operating the apparatus for manufacturing the resin roll R using the molding die 216 described above, heat is applied to the fluid resin material M inside the cavity 218, and the desired resin roll R is obtained by the completion of the reaction and curing. Can be However, the following problems are pointed out by this manufacturing process.
{Circle around (1)} Basically, it is a batch process, and it is difficult to perform continuous production, that is, production that is efficient and greatly reduces production costs.
{Circle around (2)} Since the heating of the fluid resin material M can basically be performed only from the outside, the reaction / curing of the fluid resin material M injected into the cavity 218 varies depending on the site. . As a result, the physical properties of the resin roll R to be obtained become heterogeneous, and a suitable roll R cannot be produced. In particular, the urethane foam forming the obtained resin roll R is a good heat insulator, and the previously reacted / cured surface portion acts as a heat insulator, so that heat is further inward from the reacted / cured surface portion. It cannot be transmitted efficiently. Therefore, the physical properties of the obtained resin roll R become largely inhomogeneous in the radial direction.
{Circle around (3)} In order to reduce the adverse effects of the heating and shorten the time required for the reaction and heating, it is common to preheat the mold 216 and the core 228. In this case, in the manufacturing process, the above-described heating is performed before the fluid resin material M is injected into the molding die 216, and the raw material M is injected into the injection hole 224 ( 19 and 20), the reaction / hardening starts sequentially from the part near the injection hole 224 where the fluid resin material M comes into contact most quickly, as shown in FIG. As a result, a serious disadvantage is pointed out that resin rolls R having different physical properties are produced along the injection path of the fluid resin material M (in this case, the axial direction of the obtained resin roll R).
(4) As means for avoiding the problems described in (2) and (3) above, the flowable resin raw material M is applied over a long period of time from a low temperature while eliminating the temperature difference in the raw material M. A method of gradually heating is conceivable. However, in this case, it is apparent that excessive heating is required and that batch processing is not suitable for actual industrial mass production in view of the fact that a shorter cycle time is better.
[0008]
[Object of the invention]
The present invention has been proposed in view of the problems inherent in the conventional technology described above, and has been proposed in order to preferably solve the problem, and uses a formed pipe having an inner diameter substantially equal to the outer diameter of a resin roll to be obtained. Here, by using a long sheet for regulating the outer shape of the resin roll, the fluid resin material is heated and reacted and cured while being transported, so that there is no difference in hardness and the like continuously and depending on the part. It is an object of the present invention to provide an apparatus capable of efficiently manufacturing a resin roll having substantially the same resin.
[0009]
[Means for Solving the Problems]
In order to solve the above-described problems and appropriately achieve the intended purpose, the resin roll manufacturing apparatus according to the present invention has an inner diameter substantially equal to the outer diameter of the resin roll to be obtained, and is provided from the upstream side to the downstream side of the manufacturing line. The required number of molded pipes arranged in series towards the side,
A long sheet supply device that is arranged on the upstream side of the forming pipe located at the most upstream and supplies a long sheet along the production line,
Disposed on the downstream side of the long sheet supply device, the long sheet is gradually formed into a cylindrical shape along with the supply of the long sheet, and both ends along the longitudinal direction of the long sheet are brought close to each other. A long sheet cylinder device provided with a regulating member that forms a long cylindrical body that can pass through the inside of the forming pipe,
In the process in which the long sheet is formed into a tubular shape by the long sheet cylinder device, a raw material injection device that injects a flowable resin raw material into an upper opening region of the long sheet,
With respect to the flowable resin raw material that is disposed in the vicinity of the plurality of forming pipes and is transported in the forming pipe while being surrounded by the long cylindrical body, at least the amount of heat required for the reaction and curing of the material is induced by the principle of induction heating. A heating device for applying;
It is arranged on the downstream side of the molding pipe at the most downstream side, and is constituted by a long roll material pulling device that pulls and transfers the long cylindrical body together with the long resin roll material formed inside. .
[0010]
In order to solve the above-described problem and appropriately achieve the intended purpose, a resin roll manufacturing apparatus according to another invention of the present application has an inner diameter substantially equal to the outer diameter of a resin roll to be obtained, and is provided upstream of a manufacturing line. A required number of formed pipes arranged in series from the side to the downstream side,
A long sheet supply device that is disposed on the upstream side of the forming pipe located at the most upstream and supplies the first long sheet and the second long sheet along the production line;
A long sheet disposed downstream of the long sheet supply device and capable of gradually forming the first long sheet into a cylindrical shape as the first long sheet is supplied and passing through the inside of the forming pipe; A long sheet cylinder having a cylindrical member and a regulating member for covering the second long sheet so as to prevent leakage of the flowable resin material from both ends along at least the longitudinal direction of the long cylinder. Equipment and
A raw material injection device for injecting a flowable resin raw material into an upper opening region of the first long sheet in a process in which the first long sheet is formed into a cylindrical shape by the long sheet cylinder device;
The amount of heat required for the reaction and curing of the flowable resin raw material that is disposed in close proximity to the plurality of forming pipes and is transported in the forming pipe in a state surrounded by at least the long cylindrical body is at least an induction heat generation principle. A heating device imparted by
It is arranged on the downstream side of the molding pipe at the most downstream, and together with a resin roll long object formed inside, a roll long object pulling device that pulls and transfers at least the long cylindrical body. I do.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, an apparatus for manufacturing a resin roll according to the present invention will be described below with reference to the accompanying drawings by taking a preferred embodiment. The same members as those already described in the section of the related art are denoted by the same reference numerals, and the description thereof will be omitted. The inventor of the present application uses a molded pipe having an inner diameter substantially equal to the outer diameter of a resin roll to be obtained when manufacturing a urethane foamed resin roll (hereinafter, referred to as a resin roll) by, for example, a mechanical floss method. By controlling the outer shape of the resin roll and reacting and curing at least by the principle of induction heat generation (heating) while transferring the flowable resin material, there is almost no difference in various physical properties such as hardness inside, That is, they have found that a resin roll exhibiting highly uniform physical properties can be manufactured continuously. In the present invention, the expression that both end edges along the longitudinal direction are close to each other includes a state where the both end edges are in contact with each other. The term “cylindrical body” is intended to include a shape close to a perfect circle, an ellipse, and the like, and further includes a polygonal shape with a chamfered corner.
[0012]
(About the overall configuration of the resin roll manufacturing device)
The manufacturing apparatus 10 forming a resin roll manufacturing line according to the embodiment is basically configured in a linear line shape, and as shown in FIG. 1, a plurality of manufacturing apparatuses 10 are arranged in series from the upstream side to the downstream side of the manufacturing apparatus 10. A required number of formed pipes 20 are arranged, and a first long sheet 92 (hereinafter, referred to as a first sheet 92) and a second long sheet 94 (hereinafter, referred to as a first sheet 92) are arranged along the line at the uppermost stream. A long sheet supply device 24 for continuously supplying the second sheet 94), and an inner side provided downstream of the long sheet supply device 24 and obtained by gradually forming the first sheet 92 and the second sheet 94 into a cylindrical shape. A long sheet cylinder device 30 forming a long double cylindrical body 90 comprising a long cylindrical body 93 and an outer long cylindrical body 95, and a flowable resin material M is injected into the cylindrical body 90. Raw material injection device 50 and fluid resin raw material in cylindrical body 90 , A continuous roll pulling device 70 that continuously pulls and transfers the cylindrical body 90 at the most downstream side of the pipe 20, and a long resin roll obtained at the downstream side of the device 70. It basically includes a long sheet peeling device 72 that continuously peels the cylindrical body 90 from the outer peripheral surface of the object LR and returns it to a sheet shape, and a roll cutting device 74 that cuts the long object LR to a required length. Have been. In the present embodiment, the upstream side and the downstream side respectively refer to a starting point side and an end point side in the manufacturing line with a predetermined position as a base point. The following description of each component device is basically made in order from the upstream side of the manufacturing line in accordance with the flow of the manufacturing process.
[0013]
(About the molded pipe 20)
The forming pipe 20 has an inner diameter substantially equal to the outer diameter of the resin roll R to be finally obtained, and is a constituent member arranged from an upstream side to a downstream side of a manufacturing line forming the manufacturing apparatus 10. Specifically, the fluid resin material M to be heated therein is heated while being transported while being surrounded by the sheets 92 and 94 to form the resin roll long material LR which is the base of the resin roll R. It is a member. Considering the easy operation of the actual manufacturing apparatus 10, as shown in FIG. 1, a heating apparatus 60 to be described later ([0035]) has at least a corresponding function for each of the heating mechanisms 64 and 66 for heating each part. And a plurality of formed pipes 20 arranged in series. In this case, the plurality of formed pipes 20 are arranged so that their central axes are aligned with each other. The material of the molded pipe 20 is, for example, a glass sheet so as to be able to basically withstand heating to a predetermined temperature by the heating device 60 and to perform efficient heating based on the above-described induction heating principle and dielectric heating principle. It is preferable to use a so-called non-magnetic substance and a substance having a small dielectric loss, which is manufactured by impregnating an epoxy resin having high heat resistance (specifically, about 150 ° C.). Since a suitable material for this material changes depending on the heating principle of each of the heating mechanisms 64 and 66 described later ([0038] to [0040]), it will be described together with the description of the heating mechanisms 64 and 66 and the like.
[0014]
The inner diameter of the molded pipe 20 is set to be substantially equal to the outer diameter of the resin roll R to be finally obtained, as described above. It should be noted here that the roll R obtained in the present invention is a roll obtained by a mechanical floss method, that is, a required foaming gas is previously mixed and stirred in the fluid resin raw material M, and Even with a roll obtained by heating to accelerate the reaction and curing, a slight increase in volume cannot be avoided by the heating. This increase in volume does not occur in the molded pipes 20 arranged on the upstream side where reaction and hardening by heating hardly occur, and therefore, there is no problem in the manufacturing process. However, in the molded pipe 20 arranged on the downstream side where the progress of heating proceeds, the flowable resin raw material M is pressed against the inner peripheral surface 20a of the pipe 20 due to the increase in volume. As a result, there is a fear that the transfer of the raw material M in the pipe 20 becomes difficult.
[0015]
In the present invention, in order to avoid such a situation, both sheets 92 and 94 (described later [0020]), which are means for transporting the fluid resin material M while surrounding the same, are used. In order to avoid this more positively, as shown in FIG. 2, the inner diameter of the molded pipe 20 in which the respective heating mechanisms 64 and 66 for heating the respective parts are arranged is stepwisely changed with the flow of the production line. A method of enlargement is employed. This method is also effective in the case of the flowable resin raw material M which is foamed by, for example, a chemical foaming method and whose volume is remarkably increased to 2 to 3 times or more.
[0016]
Note that this stepwise expansion of the inner diameter is not essential. In particular, when a so-called solid raw material M that is not foamed as the fluid resin raw material M is used, the outer diameter of the resin roll R to be finally obtained may be reduced. Good production of the roll R is possible even by using only the formed pipe 20 having substantially the same inner diameter. However, by providing such an inner diameter difference, the outer diameter of the raw material M during the reaction and curing can be reliably regulated, and various adverse effects such as a reduction in the transfer speed due to expansion can be effectively avoided. Play. Further, the inner diameter of each pipe 20 may be increased stepwise so that the inner diameter is increased in a so-called trumpet shape. Further, although a plurality of molded pipes 20 are used in the present embodiment, an integrated long molded pipe may be used instead.
[0017]
(About guide sheet 76)
A guide sheet 76 is provided on the inner peripheral surface 20a of the forming pipe 20 so as to reduce friction between the first sheet 92 and the second sheet 94 transferred while being in contact with the inner peripheral surface 20a. Are extended in the longitudinal direction. The guide sheet 76 has at least two roles. That is, (1) frictional force is generated between the long double cylindrical body 90 and the inner peripheral surface 20a depending on the type of the flowable resin raw material M used and the like. The fact that the frictional force is reduced by being interposed between the peripheral surface 20a and the transfer of the long double cylinder body 90 is facilitated. When the fluid resin material M in the previous fluid state leaks to the outside, adverse effects due to the leakage are suppressed to a slight extent.
[0018]
Therefore, the guide sheet 76 needs to be disposed at a portion of the molded pipe 20 where the fluid resin material M may leak, and in order to ensure the ease of replacement, the guide sheet 76 is disposed from the most upstream to the most downstream. It is desirable to arrange them continuously over the entire length of the formed pipe 20. In consideration of this point, in this embodiment, the base point and the end point of the guide sheet 76 are located at the uppermost stream and the lowermost stream of the molded pipe 20, respectively, so that the inner peripheral surface 20a thereof extends over the entire length of the pipe 20. It has been extended. Further, a guide sheet collecting mechanism 23 capable of continuously winding the guide sheet 76 in a roll shape at the base point and enabling the guide sheet 76 to be rolled up at the end point is provided. The guide sheet 76 in the formed pipe 20 can be wound up and replaced as necessary. The material and the like of the guide sheet 76 are mainly made of aramid fiber in consideration of the heating by the heating device 60 and the friction reducing property, and are woven into a required sheet shape and coated with a fluororesin or a silicone resin. Long objects are preferably used. As the main body of the guide sheet 76, in addition to aramid fiber, aramid paper, polyimide film, PPS (polyphenylene sulfide) film, or the like can be used. In view of factors such as the length and inner diameter of the molded pipe 20 and required heat resistance, it is sometimes difficult to reduce friction by directly applying a fluororesin or silicone resin to the inner peripheral surface 20a. is there. In such a case, the guide sheet 76 is an alternative means that can realize the friction reduction processing very simply and effectively.
[0019]
(About the long sheet feeding device 24)
The long sheet supply device 24 is disposed at the uppermost stream of a series of devices in the manufacturing line, and includes a first long sheet supply mechanism 26 including a roll body around which the first sheet 92 is wound in a roll shape; And a second long sheet supply mechanism 28 having a roll body in which two sheets 94 are wound in a roll shape. The long sheet feeding device 24 functions as a means for regulating the outer shape of the resin roll R to be obtained by surrounding the flowable resin material M and transferring the flowable resin material M through the inside of the molding pipe 20. This is a device for continuously or indirectly supplying the first sheet 92 and the second sheet 94 to be used. Specifically, a first long sheet supply mechanism 26 and a second long sheet supply mechanism 28, which are supply sources of the rolled first sheet 92 and second sheet 94, respectively, are provided. The first sheet 92 and the second sheet 94 are configured to be supplied along. In addition, the first sheet 92 and the second sheet 94 are formed by applying the flowable resin raw material M from the inner side to the first sheet 92 and the second sheet 94 by the long sheet cylinder device 30 described later ([0023]). (See FIG. 2A). The supply of the first sheet 92 and the second sheet 94 from the first long sheet supply mechanism 26 and the second long sheet supply mechanism 28 is performed by a roll long object pulling device 70 described later ([0044]). Since the roll is supplied by being pulled, it is not particularly positively supplied. However, the roll may be positively driven and fed out if necessary.
[0020]
The first sheet 92 and the second sheet 94 are continuously supplied from the long sheet supply device 24, and are wound and collected by a long sheet peeling device 72 described later ([0048]). That is, the long sheet supply device 24 can be regarded as a paired device with the long sheet peeling device 72. The driving force for the first sheet 92 and the second sheet 94 to pass through the manufacturing line, that is, the plurality of forming pipes 20 is the same as the forming pipe 20 arranged at the most downstream side and the long sheet peeling device. 72, provided by a long roll pulling device 70 disposed between the two rolls.
[0021]
Further, the first sheet 92 and the second sheet 94 function as means for regulating the outer shape of the resin roll R to be obtained by surrounding the fluid resin material M and transferring the inside of the pipe 20 as described above. Is what you do. For this reason, heat resistance to the heat applied when reacting and curing the fluid resin material M, releasability from the obtained resin roll R, low frictional property when transferred in the molding pipe 20 and It is required to have a mechanical strength (tensile strength) or the like that can withstand the tensile force of the long roll tension apparatus 70. The heat resistance is required to react and cure the generally used fluid resin material M, for example, at least 130 ° C. or more in consideration of use at 110 ° C. It is appropriately selected to have properties such as a material and a thickness that can withstand the tensile force urged by the device 70. For example, a paper material, a resin sheet, or the like having electrical insulation properties and having a surface subjected to release treatment may be used. Further, the overall length in the lateral direction of the second sheet 94, that is, the width is set to be at least as large as the width of the first sheet 92 (details will be described later ([0027])).
[0022]
Regarding various processes such as the above-described releasability of the first sheet 92, in consideration of direct contact with the fluid resin material M, the releasability of the first sheet 92 on the material M supply side is reduced. Processing that contributes to Further, since the second sheet 94 is in direct contact with the inner surface 20a of the molded pipe 20, the side of the second sheet 94 facing the inner peripheral surface 20a is subjected to a process contributing to low friction. Further, the side of the first sheet 92 and the second sheet 94 that are in contact with each other may be subjected to a process of reducing friction.
[0023]
(About the long sheet cylinder device 30)
As shown in FIG. 3, the long sheet cylinder device 30 is disposed between the long sheet supply device 24 and the uppermost stream forming pipe 20 and includes a plurality of regulating members provided at predetermined intervals. And a common base 38 capable of supporting the respective plate-like members 32 upright. Then, the first sheet 92 and the second sheet 94 are gradually formed into a tubular shape, and finally, the inside of the formed pipe 20 is allowed to pass, and the first sheet 92 and the second sheet 94 are respectively formed in the respective longitudinal directions. Are overlapped with each other to form a long double cylindrical body 90. The long double cylindrical body 90 is formed of the first sheet 92 and has an inner long cylindrical body 93 that directly surrounds the liquid resin material M having fluidity while preventing leakage, and the second sheet 92. And an outer long cylindrical body 95 surrounding the long cylindrical body 93 from the outside (see FIG. 2A). In the long sheet cylinder device 30, the first sheet 92 and the second sheet 94 are formed into a cylindrical shape in cross section, that is, formed into the two cylindrical bodies 93 and 95 in series along the production line. This is performed by the plurality of plate members 32 arranged.
[0024]
Each of the plurality of plate-like members 32 has a first slit 34 and a second slit 36 each having substantially the same cross-sectional shape as required for the first sheet 92 and the second sheet 94 according to the arrangement position. And the first sheet 92 and the second sheet 94 can be inserted therethrough. The common base 38, which is a main part of the long sheet cylinder device 30, includes a plurality of grooves 38a in which the plate-like members 32 can be arranged orthogonally to the manufacturing line. ing. That is, the respective plate-like members 32 are finely adjustable in the vertical and horizontal directions with respect to the production line by the common base 38 and are supported in series at required intervals. Specifically, the first sheet 92 and the second sheet 94 passing through the first slits 34 and 36 are aligned with the center axis along the supply path with respect to the production line, and maintain a substantially parallel state here. It is configured as follows.
[0025]
As shown in FIG. 4, the first slits 34 and the second slits 36 are provided at the respective arrangement positions of the plurality of plate members 32 arranged along the production line. It has a shape corresponding to the cross-sectional shape required for the H.94. That is, the first sheet 92 and the second sheet 94 are passed through the long sheet cylinder device 30 so that both end edges 92a, 92a and 94a, 94a along the longitudinal direction are overlapped respectively. At the same time, they are formed into a long cylindrical body 93 and a long cylindrical body 95 in which the resin roll R to be obtained and the central axis are aligned, respectively, and finally constitute the long double cylindrical body 90. .
[0026]
In this way, the first sheet 92 and the second sheet 94 gradually formed into the long cylindrical body 93 and the long cylindrical body 95 have a sectional shape in the middle of the path of the long sheet cylinder device 30. Has a U-shape, that is, a so-called upwardly opened arc. In a later stage of forming the first sheet 92 and the second sheet 94 into the long cylindrical body 93 and the long cylindrical body 95, each of the sheets 92 and 94 has a substantially cylindrical cross section. . Therefore, for example, depending on the position on the downstream side or the like of the long sheet cylinder device 30, the first sheet 92 and the second sheet 94 can be divided into two cylindrical bodies only by the second slit 36 formed in the plate member 32. 93 and 95 (see FIG. 4). That is, with respect to the plate-like member 32 on the required downstream side of the long sheet cylinder device 30, only the second slit 36 is provided, so that the manufacturing cost of the plate-like member 32 can be reduced. is there.
[0027]
As shown in FIG. 5, the flowable resin material M is injected into the first sheet 92 in the upper opening state, that is, the state having the upper opening area, by the raw material injection device 50 (see details). See below ([0029]). After the injection of the fluid resin material M, the upper opening of the first sheet 92 is gradually closed, and the outer peripheral side is covered with the second sheet 94. At this time, the first sheet 92 and the second sheet 94 finally have a long cylindrical body 93 and a long cylinder 93 each having overlapping portions 92b, 94b in which the both end edges 92a, 92a and 94a, 94a are overlapped. Since the length of the second sheet 94 in the short direction is set to be longer than the width of the first sheet 92, the long cylindrical body 93 is formed as a long cylindrical body. 95 completely covered. With such a structure, even when the fluid resin material M in a flowing state leaks from the long cylindrical body 93, the material M leaks out of the long double cylindrical body 90. Can be avoided.
[0028]
As shown in FIG. 6, a long member provided as a regulating member includes a plurality of rollers 102 arranged substantially perpendicularly to the advancing (supplying) direction of the second sheet 94 forming the outside of the long double cylindrical body 90. It is also possible to employ the sheet cylinder device 100. The plurality of rollers 102 are formed according to the arrangement position thereof, that is, in forming the second sheet 94 into the long cylindrical body 95 so as to form the second sheet 94 into the long cylindrical body 95 from which the second sheet 94 is to be obtained. The arrangement angle, the number of arrangements, and the like are appropriately set according to the degree. Here, it is described that the second sheet 94 located on the outer side is formed. However, the first sheet 92 existing inside the second sheet 94 and having a small width is formed of the second sheet 94. There is no particular problem because the elongate cylindrical body 95 is inevitably formed into the elongate cylindrical body 93 along with the elongate cylindrical body 95. In addition, as the long sheet cylinder device, a block body having the required shape of each portion of the second slit 36 continuously may be used, or the roll 102 may be replaced with a conveyor of a required length.
[0029]
(About the raw material injection device 50)
The raw material injecting device 50 is a device for controlling and injecting a fluid resin material M prepared in advance into an upper opening area of the first sheet 92, and a material tank for storing the fluid resin material M. (Not shown). The fluid resin material M used in the present embodiment is, as described above, a material such as a polyol and an isocyanate that becomes a urethane resin by a mechanical floss method, and a dry air or nitrogen or the like that becomes a cell after reacting and curing the material. It is manufactured by mixing with a foaming gas such as an inert gas. The flowable resin raw material M refers to a general resin raw material having fluidity that can be poured at the temperature at the time of molding. Depending on the physical properties required for the obtained resin roll R and the like, the raw material and foaming may be appropriately performed. The properties, such as no, are determined. As the material, for example, general resins such as urethane, urea, NBR latex, acrylic latex and PVC latex can be used. As for the properties of the raw materials, as described above, any of solid, foamed raw materials by mechanical foaming, and foamed raw materials by chemical foaming may be used as long as they are in a fluidized state in the operating temperature range. The dielectric constant is 1.1 or more and the dielectric loss (coefficient) is 1 × 10 so that self-heating based on the principle of dielectric heating can be achieved. ^-3 Preferably, more than 30 compositions are used.
[0030]
The injection amount of the flowable resin raw material M injected from the raw material injection device 50 is set to be the volume of the resin roll R to be obtained by surrounding the raw material M to be supplied in the first sheet 92 which is sequentially transferred. It is determined by calculating. That is, the cross-sectional area of the resin roll R to be obtained is A (cm ² ), And when the speed of the first sheet 92 to be transferred is B (cm / sec), the injection amount of the flowable resin raw material M is A × B (cm ³ / Sec), and the supply weight per unit time can be calculated from the density of the raw material M. When a foaming raw material by a chemical foaming method in which a foaming agent is mixed is used as the fluid resin raw material M, in addition to the above-described elements, a volume increase due to a foaming ratio in the raw material is taken into consideration. A determination of the injection volume is made.
[0031]
The arrangement position of the raw material injection device 50 is particularly problematic as long as the flowable resin raw material M can be injected into the upper opening region of the first sheet 92 in the long sheet cylinder device 30. There is no.
[0032]
(About the sealing device 80)
In the present embodiment, as shown in FIG. 7, the long sheet cylinder device 30 moves the metal block 82 of a heat conductor having a built-in electric heater in the vertical direction to a position immediately after the overlapping portion 92b is formed. A sealing device 80 that can be provided is provided. As shown in FIG. 8, the sealing device 80 causes the fluid resin material M in the pressed portion to react locally and instantaneously by contacting and pressing the metal block 82 near the overlapping portion 92b. It is to be cured. That is, the fluid resin material M in a portion where there is a possibility of leakage is positively reacted and cured, thereby preventing the fluid resin material M from leaking further. This further enhances the ability of the fluid resin material M to be prevented from leaking to the outside from both end edges 92a along the longitudinal direction.
[0033]
The fluid resin material M preferably has a low viscosity and a high fluidity in consideration of its injectability and the like. However, in such a state, as shown in FIG. 9, a case where a small amount of the fluid resin material M intervenes in the polymerization section 92b is assumed. In such a case, by reacting and curing only a small amount of the leaked fluid resin material M in the polymerization section 92b, it can be used as an adhesive component of the polymerization section 92b. Prevention of leakage of the fluid resin material M can be expected (see FIG. 9A). Further, the amount of leakage of the fluid resin material M is large, and even in the case where the fluid resin material M leaks from the polymerization section 92b, in or near the polymerization section 94b that further covers the polymerization section 92b from outside. The reaction and curing are performed similarly (see FIG. 9B).
[0034]
Note that, instead of the metal block 82, a metal roller of a good heat conductor similarly having a built-in electric heater may be used. In this case, the metal roller is also rotated in accordance with the transfer of the long double cylinder 90, and in particular, friction does not occur between the metal roller and the long double cylinder 90, and the roll length is reduced. This is preferable because no load is applied to the pulling device 70. When the positions of the polymerization sections 92b and 94b are different from each other, the reaction and curing of the flowable resin raw material M in or near the polymerization section 94b is performed, for example, along a line where the polymerization section 94b is to be formed. The arrangement may be such that a line heater or the like is disposed in the first slit 34 and / or the second slit 36. Further, as shown in FIG. 10, even when both end edges 92a and / or 94a along the longitudinal direction are not overlapped, the flowable resin material M in the vicinity thereof is reacted and cured to form the material M. Can be prevented from leaking.
[0035]
(About the heating device 60)
The heating device 60 is disposed on the downstream side of the long sheet cylinder device 30, and the fluid resin material injected into the long double cylindrical body 90 being transferred through the cylinder device 30. The amount of heat required for reaction and curing is supplied to M. That is, the heating device 60 includes an external heating mechanism 64 that heats the fluid resin material M using the principle of induction heating and an intermediate heating mechanism 66 that heats the fluid resin material M using the principle of dielectric heating. Basically, in this embodiment, the external heating mechanism 64 and the intermediate heating mechanism 66 are arranged in this order from the upstream side to the downstream side (see FIG. 2). In the present invention, the principle of induction heating and the principle of dielectric heating are employed as the heating method. For example, as shown in FIG. 11, a portion of the flowable resin material M near the inner periphery of the molding pipe 20 (hereinafter, referred to as an outer peripheral region OP) is heated by the induction heating principle, and further, the outer periphery described above by the dielectric heating principle. The intermediate region MP surrounded by the region OP is heated.
[0036]
In the present embodiment, the external heating mechanism 64 is configured to apply an AC voltage to the induction coil 63 wound around the outer periphery of the forming pipe 20 to heat the same, and the intermediate heating mechanism 66 is A high-frequency voltage is applied to a pair of electrodes 67, 67 disposed opposite to each other with the pipe 20 interposed therebetween to heat the pair. The induction heating principle is a principle in which a current (frequency: 50 Hz to 40 MHz) is caused to flow through an induction coil to generate an induction current in a magnetic body existing in the magnetic flux, thereby causing the magnetic body to generate heat. The dielectric heating principle refers to a principle in which an object to be heated is present in a high-frequency AC electric field of 350 KHz to 40 MHz to activate molecular motion of the object to be heated to generate self-heating.
[0037]
Therefore, as is apparent from the above-described configuration, the heating of the outer peripheral region OP and the intermediate region MP in the fluid resin material M is performed by using the external heating mechanism 64 using the induction heating principle and the dielectric heating principle in the heating device 60. Each of them is sequentially and individually performed by the intermediate heating mechanism 66. In the present embodiment, basically, the external heating mechanism 64 and the intermediate heating mechanism 66 are arranged in series in this order, and the heat retaining mechanism 69 is arranged after the intermediate heating mechanism 66, that is, at the most downstream side. .
[0038]
The external heating mechanism 64 is a device that selectively reacts and cures the outer peripheral region OP in the fluid resin material M using the principle of induction heating. Specifically, at the portion of the external heating mechanism 64, a cylindrical body 64a made of a magnetic material that self-heats by the induction heating principle is provided on an outer peripheral portion of the forming pipe 20 (see FIG. 2). The tubular body 64a is self-heated by the principle of induction heating, whereby the temperature of the molding pipe 20 is increased, and the heat causes the outer peripheral region OP of the fluid resin material M to selectively react and harden. The thickness of the tubular body 64a is preferably reduced in order to increase the temperature efficiency with respect to the energy to be supplied. Alternatively, the tubular member 64a may not be disposed, and the molded pipe 20 at a position corresponding to the external heating mechanism 64 may be made of a magnetic material. In addition, since the cylindrical body 64a is located on the outer peripheral portion of the formed pipe 20, as shown in FIG. 12, direct heating by so-called conduction heating by a normal electric heater 65 or the like is also possible. In this case, as the tubular body 64a, for example, a metal material having good heat conduction efficiency is suitably adopted.
[0039]
The intermediate heating mechanism 66 is a device that preferentially reacts and cures the intermediate region MP in the fluid resin material M based on the principle of dielectric heating. Originally, the urethane foam (in the case of the present embodiment) obtained by reacting and curing the fluid resin material M has a high heat insulating property. Therefore, after the outer peripheral region OP in the fluid resin material M is reacted and cured by the external heating mechanism 64, it is generally difficult to quickly and efficiently heat the intermediate region MP surrounded by the outer peripheral region OP. is there. The molded pipe 20 at this portion is preferably made of a material having a small dielectric loss so that a large amount of energy can be supplied to the self-heating of the fluid resin material M based on the principle of dielectric heating.
[0040]
According to the manufacturing apparatus 10 according to the present invention, the intermediate region MP reacts and cures by self-heating based on the principle of dielectric heating, so that the above-described problem cannot occur. In addition, since the dielectric heating principle is performed by an electric field applied to the fluid resin material M to be heated, the heating portion is naturally limited to a portion existing in the electric field and capable of self-heating. In addition, since the dielectric heating principle is performed stochastically (randomly) so as to make the entire energy level uniform, heating uniformity is high. That is, when the intermediate region MP surrounded by the urethane foam acting as a heat insulating material is quickly and uniformly heated, it can be said to be an optimal method. The material of the molded pipe 20 to which the intermediate heating mechanism 66 is disposed correspondingly is preferably a substance having a small dielectric loss that does not generate heat when a high frequency voltage is applied from the pair of electrodes 67, 67. The molded pipe 20 made of the above-mentioned material can also be suitably used.
[0041]
Further, in the passage zone of the long resin roll LR covered with the long double cylindrical body 90 at the most downstream portion of the main heating device 60, the heat amount supplied from the external heating mechanism 64 and the intermediate heating mechanism 66 is provided. A heat retention mechanism 69 is provided to efficiently heat the resin roll long material LR by utilizing the heat. Specifically, this is achieved by surrounding the periphery of the formed pipe 20 at the corresponding portion with the heat insulating material 69a. That is, the amount of heat (the amount of energy) required for each of the regions OP and MP is determined by the length and output of each of the corresponding heating mechanisms 64 and 66. For this reason, if the output is increased, a sufficient amount of energy can be secured even with the theoretically short heating mechanisms 64 and 66.
[0042]
However, a certain time is required for a chemical change, that is, curing, for the fluid resin material M to become the long resin roll LR. This is because, in a chemical reaction, a reaction constant is determined by a raw material and a product (here, a flowable resin raw material M and a long resin roll material LR, respectively), and the reaction rate is determined by the constant and the like. It is. Therefore, in order to obtain a good long resin roll LR, a sufficient reaction time, that is, a length of the heating device 60 is required in addition to the outputs of the heating mechanisms 64 and 66 constituting the heating device 60. Is done. During this reaction time, the greater the amount of energy contained in the flowable resin raw material M, the higher the efficiency. Therefore, without adding excessive energy, the flowable resin raw material M loses the energy already given. In order to secure the reaction time while maintaining the temperature, the heat retaining mechanism 69 is provided. In addition, since the heat retaining mechanism 69 only needs to maintain at least the heat given by each of the heating mechanisms 64 and 66, the predetermined thermal heating means is used instead of the heat insulating material 69a to positively maintain the heat. May be implemented.
[0043]
In the present embodiment, the main heating mechanisms 64 and 66 are arranged in the order of the external heating mechanism 64 and the intermediate heating mechanism 66 as described above, and by arranging in this order, the following effects can be expected. . That is,
{Circle around (1)} The reaction and curing of the fluid resin material M in the outer peripheral region OP is performed in a state where the fluid resin material M is not reacted and cured, that is, before being affected by heating and volume expansion due to the reaction. This can effectively prevent the fluid resin material M from leaking out of the long double cylindrical body 90.
{Circle around (2)} The time lag between the reaction and curing in each of the regions OP and MP causes a difference in physical properties such as a difference in hardness in the radial direction of the resin roll R to be obtained. However, after applying a controlled heat to obtain the outer peripheral region OP and reacting and curing only the minimum thickness as the outer peripheral region OP, most of the remaining fluid resin material M is once removed. If the reaction and curing are performed according to the principle of dielectric heating, the difference in the physical properties is suppressed to a minimum, and as a result, a good resin roll R having uniform physical properties can be manufactured.
Further, since each of the regions OP and MP in the fluid resin material M is directly heated, a problem is caused due to a heat insulating effect of the urethane foam formed by the reaction and curing of the fluid resin material M. As a result, the time required to supply the required amount of heat, that is, the manufacturing time, can be reduced. The arrangement order of the heating mechanisms 64 and 66 is not limited to this order.
[0044]
(Regarding the long roll tension device 70)
The roll long-object pulling device 70 is basically a sandwich conveyor, and is disposed on the downstream side of the molding pipe 20 disposed at the most downstream position, and the resin obtained by passing through each device up to this point. It is composed of a pair of belts 70a, 70a that continuously pull and transfer the long double cylindrical body 90 containing the long roll object LR under control. The pair of belts 70a, 70a are configured to be rotatable in a horizontal direction and synchronously, and are arranged such that their flat outer peripheral surfaces face each other. Further, the pair of belts 70a, 70a can be arbitrarily separated from each other, and are configured so that a constant force is always urged in a direction in which the belts 70a approach each other. It is possible to securely hold the small cylindrical body 90 without depending on the dimensions (only the long double cylindrical body 90). More specifically, as shown in FIG. 13, the long double cylindrical body 90 is pulled together with the long resin roll LR from both sides in a sandwich state and pulled downstream.
[0045]
As described above, the long double cylindrical body 90 is continuously transferred from the upstream side to the downstream side while always in contact with the inner peripheral surface 20a side of the forming pipe 20. Then, in order to reduce the transfer resistance due to the contact with the inner peripheral surface 20a and transfer the long double cylindrical body 90, that is, to manufacture the resin roll long object LR satisfactorily, the inner peripheral surface 20a has Various treatments such as using a guide sheet 76 for reducing friction and gradually expanding the inner diameter of the formed pipe 20 are performed. Further, in the long roll pulling device 70, the long double cylindrical body 90 is pulled and transferred together with the long resin roll LR molded therein and having a predetermined mechanical strength. Therefore, there is no occurrence of such a situation that the cylindrical body 90 is broken when the double-sized cylindrical body 90 is pulled. Since the long resin roll LR can be elastically deformed, even if it is sandwiched from both sides by the sandwich conveyor, it returns to its original shape after releasing the sandwiched state.
[0046]
As shown in FIG. 14, instead of the sandwich conveyor, a sandwich conveyor whose sandwiching portion substantially matches the outer shape of the long double cylindrical body 90 may be used. In this case, the deformation of the long material LR is eliminated because the resin roll long material LR is not forcedly pinched and the contact area with the long double cylindrical body 90 is increased. As well as good pulling and transfer.
[0047]
By going through each apparatus up to this point, a long resin roll LR serving as a base of the resin roll R to be obtained is obtained. Accordingly, for example, peeling of the long double cylindrical body 90 that regulates the outer shape of the resin roll R, which is required for the obtained resin roll long object LR, or the resin roll length By performing post-processing in general, such as cutting of the long piece LR to a required length, the resin roll R can be obtained. Various forms such as manual or automatic can be considered for each of these post-processings. In the present embodiment, the various post-processings described above are performed by the devices described below.
[0048]
(About the long sheet peeling device 72)
The long sheet peeling device 72 is provided downstream of the roll long material pulling device 70 and continuously peels the long double cylindrical body 90 from the outer peripheral surface of the resin roll long material LR. is there. In the present embodiment, the long sheet peeling device 72 separates the long double cylindrical body 90 from the resin roll long material LR into a sheet, and obtains the first sheet obtained by this sheet-like peeling. A first long sheet collecting mechanism 72a and a second long sheet collecting mechanism 72b for separately winding and collecting both the sheet 92 and the second sheet 94 in a roll shape are provided. Then, the first sheet 92 and the second sheet 94 collected in a roll shape are supplied as they are from the first long sheet supply mechanism 26 and the second long sheet supply mechanism 28 to the first sheet 92, 94 can be used.
[0049]
The first long sheet collecting mechanism 72a and the second long sheet collecting mechanism 72b are driven under control at a winding speed substantially equal to the pulling speed urged by the roll long object pulling device 70. The first sheet 92 and the second sheet 94 to be always collected are given an appropriate tension, and are collected so as to be easily reused while avoiding wrinkles and the like. In the present embodiment, both the recovered first sheet 92 and the second sheet 94 are reused to reduce the manufacturing cost and the like, but any one of the first sheet 92 and the second sheet 94 is used. Only one of them may be reused. For example, when a material having a low viscosity and a high fluidity is used as the fluid resin material M, and the fear of leakage is high, the first sheet 92, which is considered to be likely to adhere to the material M due to leakage, is not collected. , Only the other second sheet 94 is collected.
[0050]
(About the roll cutting device 74)
The roll cutting device 74 serves as a resin roll R to be obtained by cutting the long resin roll material LR into a required length (see FIG. 1). Specifically, a cutter 74a that reciprocates at predetermined intervals and a resin roll long object LR obtained by peeling and collecting the first sheet 92 and the second sheet 94 from the long double cylindrical body 90 can be placed. And a base portion 74b for cutting the long resin roll LR into a required length by a cutter 74a. The cutter 74a is capable of cutting in synchronization with the pulling speed of the long roll pulling device 70, and other known cutting means can be employed. The cutting speed is set according to the pulling speed.
[0051]
(About post-processing station 78)
A post-processing station 78 for performing post-processing such as grinding of the outer peripheral surface of the resin roll R cut to a required length is provided downstream of the roll cutting device 74 (see FIG. 1). The post-processing performed in the post-processing station 78 includes achieving a high roundness by grinding the outer peripheral surface of the resin roll R, exposing a cell, and the like. Further, minute steps generated by the transfer of the overlapping portion 92b in the long cylindrical body 93 can be easily removed by grinding the outer peripheral surface.
[0052]
In the present embodiment, the long double cylinder 90 having a double structure is formed by using only the first sheet 92 and the second sheet 94. However, the guide sheet 76 is formed by using the first sheet 92 and the second sheet 94. It is configured to be transported together with the second sheet 94, that is, to transport the fluid resin material M by three long sheets 76, 92 and 94. It is also possible to manufacture the resin roll R by molding into a cylindrical body. In this case, the guide sheet 76 is continuously supplied by the guide sheet supply mechanism 22 and is recovered while being formed into a sheet by the guide sheet recovery mechanism 23. Further, the driving force required for the transfer is urged by the roll long object pulling device 70 in the same manner as the long double cylindrical body 90, so that the arrangement position of the guide sheet collecting mechanism 23 is It will be set on the downstream side. In this case, by transferring only the guide sheet 76, two long cylindrical bodies 93 and 95 located inside the sheet 76 and formed from the first sheet 92 and the second sheet 94, respectively. Is transported.
[0053]
[Modification example]
In the embodiment, as the cylindrical body that regulates and surrounds the outer shape of the resin roll R, the long double cylindrical body 90 duplexed by the first sheet 92 and the second sheet 94 is used. The present invention is not limited to this. For example, the resin roll R may be manufactured by using a long cylindrical body 93 made of the long sheet by a long sheet cylinder device 110 shown in FIG. In this case, as shown in FIG. 16, both end edges 92a, 92a along the longitudinal direction of the long cylindrical body 93 can reliably prevent leakage of the flowable resin raw material M, so that the overlapped portion 92b is formed. (See FIG. 16A). Further, by adjusting the viscosity of the flowable resin raw material M and using the sealing device 80, the resin roll R can be manufactured in a state where the overlapping portion 92b is not formed (see FIG. 16B). Is also possible. The configuration of the long sheet cylinder device 110 is substantially the same as that of the long sheet cylinder device 30. The second slit 36 is not formed in each plate member 32, and only the first slit 34 is provided. It is different in that it is.
[0054]
In the production of the resin roll R using the long sheet cylinder device 110, since the second sheet 94 is not used, each device / mechanism related to the sheet 94 becomes unnecessary. This has the effect of reducing operating costs. On the other hand, as compared to the long double cylinder 90, the force per unit applied at the time of tension is increased, so that the first sheet 92 with respect to the tensile force urged by the roll elongated object tensioning device 70. Care must be taken regarding tensile strength. Note that the long sheet cylinder device 100 described above ([0028]) can also be adopted.
[0055]
[Another modification example]
In addition, the width dimension of the second sheet 94 is shortened, and a long cylindrical body 93 made of the first long sheet 92 as shown in FIG. The resin roll R may be manufactured so as to cover between the both edges 92a, 92a along the longitudinal direction and the overlapping portion 92b formed by overlapping the both edges 92a, 92a. The configuration of the long sheet cylinder device 120 is substantially the same as that of the long sheet cylinder device 110 described above, and the plate member 32 is not provided with the second slit 36 but only the first slit 34. At the same time, the second sheet 94 continuously supplied from the long sheet supply device 24 (the second long sheet supply mechanism 28) is disposed on the downstream side of the raw material injection device 50 in the second long form. The first sheet 92 is configured to be guided and given to a predetermined position of the first sheet 92 by the sheet guide device 40. The second long sheet supply mechanism 28 may be integrated with the second long sheet guide device 40 separately from the long sheet supply device 24.
[0056]
The second sheet 94 does not cover the entirety of the long cylindrical body 93 made of the long sheet, but flows between both end edges 92 a of the cylindrical body 93 along the longitudinal direction or from the overlapping portion 92 b. It only needs to be present to the extent that leakage of the conductive resin material M can be avoided. Also, in order to prevent the fluid resin material M from leaking efficiently from the second sheet 94, it is preferable to provide a necessary adhesive means to the side of the second sheet 94 that contacts the long cylindrical body 93. . Instead of this adhesive means, a required adhesive means may be employed.
[0057]
In the production of the resin roll R using the long sheet cylinder device 120, since the second sheet 94 having a short width is used, the cost of the sheet 94 is reduced and the handling thereof is facilitated. This can be expected to reduce the device operation cost. On the other hand, similarly to the above-described modified example, since the force per unit applied at the time of pulling is larger than that of the long double cylinder 90, the pulling force urged by the roll long object pulling device 70 is applied. It is necessary to pay attention to the tensile strength of the first sheet 92 against the force. It is to be noted that the long sheet cylinder device 100 described above ([0028]) can be adopted also in this modification.
[0058]
【The invention's effect】
As described above, according to the apparatus for manufacturing a resin roll according to the present invention, a molded pipe having an inner diameter substantially equal to the outer diameter of the resin roll to be obtained is used, and a long pipe that regulates the outer shape of the resin roll is used here. Since the reaction and curing are performed by heating while transferring the flowable resin raw material using the sheet, there is no difference in physical properties continuously and at least in the axial direction (longitudinal direction) and further in the radial direction, and is substantially the same. Resin rolls can be efficiently manufactured without taking much time. In addition, since the fluid resin material is heated by using at least the principle of dielectric heating, a resin roll having substantially the same physical properties in the axial direction and the radial direction as described above can be efficiently and in a short time. It has an effect that can be manufactured. Further, by using the long sheets in a stacked manner, it is possible to efficiently prevent leakage of the flowable resin raw material transported in the molding pipe.
[Brief description of the drawings]
FIG. 1 is a schematic side view showing an entire apparatus for manufacturing a resin roll according to a preferred embodiment of the present invention.
FIG. 2 is a sectional view (FIG. 2 (a)) and a side view (FIG. 2 (b)) showing a part of the heating device according to the embodiment in an enlarged manner.
FIG. 3 is an enlarged perspective view showing a part of the long sheet cylinder device according to the embodiment.
FIG. 4 is an explanatory view showing the shape of each slit and second slit in a plurality of plate-like members constituting the long sheet cylinder device shown in FIG. 3 along a flow of a production line.
FIG. 5 is a flow chart showing the injection of a flowable resin raw material and the first and second long sheets into a long cylinder and a long cylinder, respectively, which are carried out by the long sheet cylinder apparatus shown in FIG. 3; FIG. 3 is a process chart showing stepwise molding of the resin.
FIG. 6 is a perspective view schematically showing a long sheet cylinder device for obtaining a long double cylinder from a first sheet and a second sheet using a roller, and a cross-sectional view at each cylinder production stage.
FIG. 7 is an enlarged perspective view showing a part of the sealing device according to the embodiment.
FIG. 8 is a diagram showing the reaction and curing of the fluid resin material at the joint portion performed by the sealing device shown in FIG. 7 when both edges along the longitudinal direction of the first long sheet are overlapped. FIG.
FIG. 9 is a diagram illustrating the flowability of a joint portion performed by the sealing device shown in FIG. 7 when both edges along the longitudinal direction of the first long sheet are overlapped and the fluid resin material leaks. It is sectional drawing which showed the mode of reaction and hardening of resin raw material.
10 shows a state of reaction and curing of a fluid resin material at a joint portion performed by the sealing device shown in FIG. 7 when both edges along the longitudinal direction of the first long sheet are not overlapped. FIG.
FIG. 11 is a cross-sectional view showing each region that can be heated by each heating method performed by the heating device according to the example.
FIG. 12 is a schematic diagram showing a case where conduction heating is used as an external heating mechanism.
FIG. 13 is an enlarged perspective view showing a part of a long roll tension apparatus according to an embodiment.
FIG. 14 is a perspective view showing a case where a sandwich conveyor corresponding to a resin roll long object whose shape is obtained is used as a roll long object pulling device.
FIG. 15 is an enlarged perspective view showing a part of a long sheet cylinder device in a manufacturing apparatus according to a modified example of manufacturing a resin roll using a single long sheet.
FIG. 16 is a schematic cross-sectional view showing a joining portion of both ends along a longitudinal direction of a long sheet in a changed row.
FIG. 17 is an enlarged view of a portion of a long sheet cylinder device in a manufacturing apparatus according to another modified example of manufacturing a resin roll using a first long sheet and a second long sheet having a short width dimension. It is a perspective view.
FIG. 18 is a schematic cross-sectional view showing a joining portion of both edges along a longitudinal direction of a first long sheet in another modified row.
FIG. 19 is a plan view showing a roll forming die used for foaming a fluid resin material in the production of a resin roll according to a conventional technique.
20 is a cross-sectional view showing an internal state when a resin roll is formed on the roll forming die shown in FIG.
FIG. 21 is a configuration diagram schematically showing an apparatus and a process for manufacturing a resin roll using a roll forming die in manufacturing a resin roll according to the related art.
FIG. 22 is a state diagram showing a state of a fluid resin material when the material is poured into the roll forming die shown in FIG. 19;
[Explanation of symbols]
20 Molded pipe
22 Guide sheet supply mechanism
23 Guide sheet collection mechanism
24 Long sheet feeder
30 Long sheet cylinder device
32 plate members
34 slits, 1st slit
36 2nd slit
38 Common base
40 Second long sheet guide device
50 Raw material injection device
60 heating device
63 induction coil
64 External heating mechanism
65 Electric heater
66 Intermediate heating mechanism
67 electrodes
69 Heat retention mechanism
70 Roll long tension device
72 Long sheet peeling device
74 Roll cutting device
76 Guide Sheet
80 Sealing device
82 metal block
78 Post-processing station
90 long double cylinder
92 Long sheet / First long sheet
92a Both edges along the longitudinal direction
92b polymerization part
93 Long cylinder
94 2nd long sheet
94a Both edges along the longitudinal direction
94b polymerization part
95 long cylinder
100 Long sheet cylinder device
110 Long sheet cylinder device
120 Long sheet cylinder device
LR resin roll long object
M Fluid resin material
MP intermediate area
OP outer peripheral area
R resin roll

Claims (13)

A required number of forming pipes (20) having an inner diameter substantially equal to the outer diameter of the resin roll (R) to be obtained and arranged in series from the upstream side to the downstream side of the production line;
A long sheet supply device (24) disposed on the upstream side of the forming pipe (20) located at the most upstream side and supplying a long sheet (92) along the production line;
The long sheet (92) is disposed downstream of the long sheet supply device (24), and the long sheet (92) is gradually formed into a cylindrical shape with the supply of the long sheet (92). A) a long sheet provided with regulating members (32, 102) forming a long cylindrical body (93) which can pass through the inside of the molded pipe (20) by bringing both end edges (92a) along the longitudinal direction of the sheet close to each other. A cylinder device (100, 110);
In the process in which the long sheet (92) is formed into a tubular shape by the long sheet cylinder device (100, 110), the fluid resin material (M) is placed in the upper opening area of the long sheet (92). A raw material injection device (50) for injection;
The liquid resin raw material (M) which is disposed close to the plurality of forming pipes (20) and is transferred through the forming pipe (20) in a state of being surrounded by the long cylindrical body (93) reacts therewith. A heating device (60) for applying at least the amount of heat required for curing by the principle of dielectric heating;
A long roll object pulling device that is disposed downstream of the most downstream forming pipe (20) and pulls and transfers the long cylindrical body (93) together with the long resin roll material (LR) formed therein. (70) An apparatus for manufacturing a resin roll, comprising: An external heating mechanism (64) for selectively heating an outer peripheral region (OP) of the long resin roll (LR) through a forming pipe (20) heated by conduction heating; The apparatus for manufacturing a resin roll according to claim 1, comprising: an intermediate heating mechanism (66) for heating an intermediate area (MP) surrounded by the outer peripheral area (OP) by a principle of dielectric heating. The heating device (60) is an external heating mechanism that heats an outer peripheral area (OP) of the long resin roll (LR) through a forming pipe (20) heated by heat generation or conduction heating based on the principle of induction heating. The (64) and an intermediate heating mechanism (66) for heating an intermediate area (MP) of the long resin roll (LR) surrounded by the outer peripheral area (OP) by a dielectric heating principle. Equipment for manufacturing resin rolls. At the most downstream side of the heating device (60), a heat retaining mechanism (69) for maintaining the temperature of the long resin roll (LR) covered with the long cylindrical body (93) is provided, and the external heating is provided. The resin roll manufacturing apparatus according to claim 2, wherein the resin roll long material (LR) heated by the mechanism (64) and the intermediate heating mechanism (66) is subjected to heat curing. The long sheet cylinder device (100, 110) includes a regulating member (32, 102), and the regulating member (32, 102) regulates the outer shape of the long sheet (92) to gradually form the long sheet (92). The apparatus for manufacturing a resin roll according to any one of claims 1 to 4, wherein the apparatus is configured to be formed into a cylindrical shape capable of allowing the inside of the pipe (20) to pass therethrough. The regulating member (32, 102) includes at least one plate-like member (32) having a slit (34) for allowing passage of the long sheet (92), and the plate-like member (32). A common base (38) that is aligned upright with the central axis along the supply path of the long sheet (92) and that stands upright at required intervals, and the slit (34) gradually moves the long sheet (92). The apparatus for manufacturing a resin roll according to claim 5, wherein the apparatus is set in a shape that can be formed into a cylindrical shape. A required number of forming pipes (20) having an inner diameter substantially equal to the outer diameter of the resin roll (R) to be obtained and arranged in series from the upstream side to the downstream side of the production line;
A long sheet supply device disposed upstream of the forming pipe (20) located at the most upstream position and supplying a first long sheet (92) and a second long sheet (94) along the production line. (24)
The first elongate sheet (92) is disposed downstream of the elongate sheet supply device (24), and the first elongate sheet (92) is gradually formed into a cylindrical shape with the supply of the first elongate sheet (92). The second long sheet is used to form a long cylindrical body (93) that can pass through the inside of the pipe (20) and to prevent leakage of the fluid resin material (M) from the long cylindrical body (93). A long sheet cylinder device (30, 100, 120) including a regulating member (32, 102) for covering the (94);
In the process in which the first long sheet (92) is formed into a tubular shape by the long sheet tubular device (30, 100, 120), the fluid resin material (M) is added to the first long sheet (92). A) material injection device (50) for injecting into the upper opening region of
The fluid resin raw material (M) which is disposed close to the plurality of forming pipes (20) and is transferred through the forming pipe (20) at least in a state of being surrounded by the long cylindrical body (93), A heating device (60) for applying at least the amount of heat required for reaction and curing by the principle of dielectric heating;
A long rolled object disposed at the downstream side of the most downstream forming pipe (20) and pulling and transferring at least the long cylindrical body (93) together with the long resin roll (LR) formed therein. An apparatus for manufacturing a resin roll, comprising: an apparatus (70). An external heating mechanism (64) for selectively heating an outer peripheral region (OP) of the long resin roll (LR) through a forming pipe (20) heated by conduction heating; The apparatus for manufacturing a resin roll according to claim 7, further comprising: an intermediate heating mechanism (66) for heating an intermediate area (MP) surrounded by the outer peripheral area (OP) by the principle of dielectric heating. The heating device (60) is an external heating mechanism that heats an outer peripheral area (OP) of the long resin roll (LR) through a forming pipe (20) heated by heat generation or conduction heating based on the principle of induction heating. The (64) and an intermediate heating mechanism (66) for heating an intermediate area (MP) of the long resin roll (LR) surrounded by the outer peripheral area (OP) by a dielectric heating principle. Equipment for manufacturing resin rolls. At the most downstream side of the heating device (60), a heat retaining mechanism (69) for maintaining the temperature of the long resin roll (LR) covered with the long cylindrical body (93) is provided, and the external heating is provided. The resin roll manufacturing apparatus according to claim 8, wherein the resin roll long material (LR) heated by the mechanism (64) and the intermediate heating mechanism (66) is heat-cured. The long sheet cylinder device (30, 100, 110) includes a regulating member (32, 102), and the regulating member (32, 102) regulates the outer shape of the first long sheet (92). The resin roll manufacturing apparatus according to any one of claims 7 to 10, wherein the apparatus is configured to gradually form a cylindrical shape capable of allowing the inside of the forming pipe (20) to pass therethrough. The regulating member (32, 102) regulates the outer shape of the second long sheet (94) to gradually form the first long sheet (92) and the second long sheet (94) into the formed pipe. The resin roll manufacturing apparatus according to any one of claims 8 to 11, wherein the apparatus is configured to be formed into a cylindrical shape capable of permitting the internal passage of (20). The regulating member (32, 102) is provided with a first slit (34) that allows the first long sheet (92) to pass through and / or at least the second length wider than the first long sheet (92). At least one plate-like member (32) provided with a second slit (36) for allowing passage of the lengthy sheet (94), and connecting the plate-like member (32) to the first long sheet (92). A common base (38) aligned upright with the center axis along the supply path and supported upright at a required interval, wherein the first slit (34) and / or the second slit (36) is provided with the first long sheet ( 92) and the second elongate sheet (94) are formed in such a shape that they can be gradually formed into a cylindrical shape, whereby the inner elongate cylinder (93) formed from the first elongate sheet (92) is formed. ) And the outside formed from the second long sheet (94) Composed long double cylinder with elongated cylindrical body (95) (90) be made with claim 12 manufacturing apparatus of the resin roll according.

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