JP2006212937A - Three-dimensional structure molded from tube, method and apparatus for producing the structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To concern a means for stably producing a three-dimensional structure in which thin, high, needle-shaped projections are formed on at least one side of a resin sheet and the three-dimensional structure which has a unique property and is produced by the means. <P>SOLUTION: In the molding means for molding the three-dimensional structure in which the needle-shaped projections are formed on at least one side of the resin sheet by pushing/inserting a large number of needle-shaped molds to/into the resin sheet, the needle-shaped mold is composed of a tube. Moreover, by further deforming the tip of the needle-shaped projection, or packing objects in a cavity in the projection, the three-dimensional structure is made to have a unique function and structure. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a three-dimensional structure manufacturing means in which needle-like protrusions are formed on one or both sides of a resin sheet using a needle-shaped mold made of a tubular body, and particularly to a three-dimensional structure manufactured thereby. It is possible to stably manufacture a three-dimensional structure having a high needle-like protrusion, and to further deform the tip of the needle-like protrusion and to fill an object into the cavity inside the protrusion. Thus, the present invention relates to a three-dimensional structure having a specific function or structure.

  A three-dimensional structure having pointed protrusions on both sides or one side of a resin sheet and a method for producing the same have been proposed (for example, Japanese Patent Laid-Open No. 48-75678). However, the disclosed three-dimensional structure has not been industrially produced because it cannot stably produce thin and long needle-like protrusions. In addition, since the disclosed tip has a thick tip, the tip is melted and removed to make a hole, and the tip has been an obstacle in melting and joining with other sheet-like materials. . Further, the disclosed structure is only required to have a high bulkiness and a high compressive strength, and the cavity inside the protrusion has not been actively used. Further, when the disclosed three-dimensional structure has a narrow tip and a long length, it is difficult to remove from the mold, and since the molded product is cooled slowly, it can be manufactured stably and continuously. There wasn't. Therefore, it has not been developed industrially, and means for stably manufacturing these structures has been demanded.

JP-A-48-75678 (first page, second page, lower left column of page 11, FIG. 1, FIG. 5).

  The present invention has been made in order to eliminate the above-mentioned drawbacks of the prior art, and the object of the present invention is to form thin and high needle-like protrusions when forming needle-like protrusions on one or both sides of a resin sheet. It is to enable stable production with high productivity. In addition, the present invention further deforms the tips of the projections of the three-dimensional structure having needle-like projections on both sides or one side of the resin sheet so that the tips of the needle-like projections are thinned, recessed, or perforated. This is to further increase the usefulness of the three-dimensional structure. Another object of the present invention is to form a three-dimensional structure having a new function by filling an object into a cavity inside the protrusion of the three-dimensional structure.

  The present invention has been made to achieve the above object, and features of the three-dimensional structure are as follows. In the present invention, the height H of the protrusion is 3 mm or more by deforming a part of the resin sheet on one side or both sides of the resin sheet, and the width W at 1/2 of H is H ≧ In a three-dimensional structure in which a large number of needle-like protrusions of 2 W are formed, the tip of the needle-like protrusion is further deformed, and the thickness of the deformed tip is less than the thickness of the side wall in the 1 / 2H portion. It relates to a certain three-dimensional structure. Further, according to the present invention, the height H of the protrusion is 3 mm or more by deforming a part of the resin sheet on one side or both sides of the resin sheet, and the width W at 1/2 of H is H The present invention relates to a three-dimensional structure in which a large number of needle-like protrusions of ≧ 2 W are formed, the tip of the needle-like protrusion is further deformed, and the deformed tip portion has a depression. In the present invention, the height H of the protrusion is 3 mm or more by deforming part of the resin sheet on both surfaces of the resin sheet, and the width W at 1/2 of H is H ≧ 2W. The present invention relates to a three-dimensional structure in which a large number of needle-like protrusions are formed, and an object is filled in a cavity formed inside the needle-like protrusion. Furthermore, the present invention relates to a three-dimensional structure in which a sheet-like material is joined at the tip of the needle-like protrusion.

  The features of the production method of the present invention are as follows. In the present invention, a plurality of needle-shaped molds are integrated with a substrate on one side of a resin sheet having fluidity when the temperature is higher than the deflection temperature of the resin. On the other surface side of the sheet, there is a perforated pressing plate that is perforated at a position corresponding to the protrusion of the needle-shaped mold. When the needle-shaped mold penetrates the resin sheet, the resin sheet is removed from the back surface. The resin sheet is deformed by moving in a direction perpendicular to the resin sheet so that the needle mold fits into the hole of the perforated pressing plate. In the manufacturing method of a three-dimensional structure in which a large number of needle-like protrusions are formed on one side, the needle-like mold is formed of a tubular body, and in the process of forming the resin sheet into the needle-like protrusion, the tubular body Fluid is flowing out or sucked from the inside of the tube The method for producing a three-dimensional structure that. In the present invention, the height h of the protrusion is 3 mm or more with respect to the resin sheet having fluidity that is equal to or higher than the resin deflection temperature, and the width w at 1/2 of h is h ≧ A large number of needle-shaped molds of 3w are integrated with the substrate, and a pair of the substrates are installed facing each other, and the needle-shaped molds of the pair of substrates move in parallel so as to penetrate each other into the resin sheet. In the method of manufacturing a three-dimensional structure in which the resin sheet is deformed by the formation of a large number of needle-like protrusions on both surfaces of the sheet, the needle-like mold is formed of a tubular body, and the resin sheet is formed on the needle-like protrusions. The present invention relates to a method for manufacturing a three-dimensional structure in which a fluid flows out or is sucked from the inside of the tube of the tubular body in the process of being molded. Further, according to the present invention, the fluid flowing out from the inside of the tube of the tubular body described above is a heated fluid, and the tip of the needle-like protrusion formed by pressing by the tubular body is further deformed by the ejection pressure of the fluid. The present invention relates to a method for manufacturing a three-dimensional structure to be added. Further, in the present invention, by being sucked from the inside of the tube of the tubular body, a hole is opened at the tip of the needle-like projection by suction pressure, or the tip of the needle-like projection is shaped into a certain shape. The present invention relates to a method for manufacturing a three-dimensional structure. Furthermore, the present invention relates to a method for manufacturing a three-dimensional structure in which an object is filled in a cavity inside a needle-like projection by flowing out a fluid from the inside of a tube of a tubular body.

  The features of the manufacturing apparatus of the present invention are as follows. In the present invention, a plurality of needle-shaped molds are integrated with a substrate on one side of a resin sheet having fluidity when the temperature is higher than the deflection temperature of the resin. On the other surface side of the sheet, there is a perforated pressing plate that is perforated at a position corresponding to the protrusion of the needle-shaped mold. When the needle-shaped mold penetrates the resin sheet, the resin sheet is removed from the back surface. The resin sheet is deformed by moving in a direction perpendicular to the resin sheet so that the needle-shaped mold fits into the hole of the perforated pressing plate. In a three-dimensional structure manufacturing apparatus in which a large number of needle-like protrusions are formed, the needle-like mold is formed of a tubular body, and in the process of forming the resin sheet into the needle-like protrusions, Fluid flows out or is sucked from the inside of the tube Apparatus for producing three-dimensional structure is constructed urchin. In the present invention, the height h of the protrusion is 3 mm or more with respect to the resin sheet having fluidity that is equal to or higher than the resin deflection temperature, and the width w at 1/2 of h is h ≧ A large number of needle-shaped molds of 3w are integrated with the substrate, and a pair of the substrates are installed facing each other, and the needle-shaped molds of the pair of substrates move in parallel so as to penetrate each other into the resin sheet. In the three-dimensional structure manufacturing apparatus in which the resin sheet is deformed to form a large number of needle-like protrusions on both surfaces of the sheet, the needle-like mold is formed of a tubular body, and the resin sheet is formed on the needle-like protrusions. The present invention relates to an apparatus for manufacturing a three-dimensional structure configured such that a fluid flows out or is sucked from the inside of the tube of the tubular body in the process of being molded. According to the present invention, a release plate having holes at positions corresponding to the needle-like projections is provided on the surface of the substrate. After the three-dimensional structure is molded, the release plate is the resin. The present invention relates to an apparatus for manufacturing a three-dimensional structure configured such that the substrate and the three-dimensional structure formed are separated by moving perpendicularly to the sheet direction. In the present invention, a release plate is provided on the opposite side of the perforated pressure plate to the resin sheet. After the three-dimensional structure is formed, the release plate is perpendicular to the direction of the resin sheet. The present invention relates to an apparatus for manufacturing a three-dimensional structure that is configured to push down the tip of the formed three-dimensional structure to separate the three-dimensional structure from the perforated pressing plate. Further, according to the present invention, a perforated pressure plate and / or a compressed air chamber is provided behind the substrate, and the resin sheet on which the needle-like protrusions are formed is formed on the perforated pressure plate by the air pressure of the compressed air chamber. And / or a three-dimensional structure manufacturing apparatus configured to be separated from the needle-shaped mold.

  The present invention is characterized by having needle-like protrusions on one or both sides of the resin sheet. Resins include polyolefins such as polyethylene and polypropylene, polycarbonates, polyamide resins such as nylon 6 and nylon 66, polyesters such as polyethylene terephthalate and polybutylene terephthalate, vinyl resins such as polyvinyl chloride and polyvinylidene chloride, polystyrene resins, acrylic acid Acrylic resins such as methyl resin, fluorine resins such as polytetrafluoroethylene, and thermoplastic resins such as polyvinyl alcohol resins are preferably used. Furthermore, even a thermosetting resin such as an epoxy resin, a phenol resin, or a urea resin can be used as long as it is a resin that exhibits fluidity at a temperature equal to or higher than the deflection temperature under load due to heating or the like. The above resins are not only used alone, but can also be used in combination with each other by blending, etc., and additives such as plasticizers, fillers, antioxidants, stabilizers, lubricants, etc. Can also be used. Since the present invention is also used for civil engineering, biodegradable resins such as polylactic acid and polybutylene succinates, and photodegradable resins such as vinyl ketone polymers are preferred. The present invention also aims at a soft three-dimensional structure, and thermoplastic elastomers such as SBS and polyurethane can also be used.

  The present invention has a large number of needle-like protrusions formed by deforming a part of the resin sheet on one side or both sides of the resin sheet. The resin sheet used here means that the resin is molded into a sheet shape. The sheet is not particularly limited in thickness, and usually includes what is called a film or a film. However, the thickness is preferably 10 μm or more and 3 mm or less, more preferably 50 μm or more and 2 mm or less, 100 μm or more. Most preferred is 1 mm or less. This is because when it does not reach 10 μm or exceeds 3 mm, it is difficult to form stably. The three-dimensional structure having needle-like protrusions according to the present invention includes a three-dimensional structure in which needle-like protrusions are formed on one side of a sheet-like object and a three-dimensional structure in which needle-like protrusions are formed on both sides of the sheet-like object. The three-dimensional structure with needle-like projections on one side can increase the number of needle-like projections on one side, so that the compressive strength is strong, and the sheet-like shape has already been formed on the bottom surface. By simply joining a sheet-like object to the tip of the protrusion, a structure having a sheet-like object on the top and bottom can be obtained. The three-dimensional structure in which needle-like protrusions are formed on both surfaces has a feature that the thickness of the three-dimensional structure is increased and the structure can be made more rugged. Therefore, whether to use a structure having needle-like protrusions on one side or a structure having needle-like protrusions on both sides is determined according to the use according to these characteristics.

  The needle-like protrusion in the three-dimensional structure of the present invention is characterized in that the height H of the protrusion is 3 mm or more. The height H of the protrusion is 3 mm or more, preferably 200 mm or less, more preferably 5 mm or more and 100 mm or less, and most preferably 8 mm or more and 50 mm or less. If it does not reach 3 mm, the bulkiness of the three-dimensional structure of the present invention cannot be satisfied, and if it exceeds 200 mm, it may be difficult to stably produce the elongated protrusions of the present invention. In addition, the width W at a position of ½ of the height H of the protrusion of the present invention is characterized by H ≧ 2W. This is because the height H can be increased with respect to W because it is a feature of the present invention. W is H ≧ 2W, preferably H ≦ 100W, more preferably H ≧ 2.5W, H ≦ 70W, H ≧ 3W, and most preferably H ≦ 50W. This is because, within these ranges, the bulkiness and porosity can be increased, and a more flexible structure can be obtained. In addition, when H <2W, it may not be possible to satisfy the bulkiness of the three-dimensional structure of the present invention. When H> 100W, it is difficult to stably manufacture the elongated protrusions of the present invention. Because there is. The protrusion does not necessarily mean only a conical symmetrical shape, and the cross section at W may have various shapes such as an ellipse, a square, and a triangle, or a mixture thereof. As the value of W in this case, the smallest value in the cross section at 1 / 2H is adopted. In one structure in the present invention, H and W do not need to be constant, and various Ws may be mixed. In addition, the measurement of H and W is obtained by measuring 30 projections selected at random and arithmetically averaging them. In addition, the requirements for the above three-dimensional structure are requirements as “things”, and those manufactured by the manufacturing method and manufacturing apparatus described below do not necessarily require the above values.

  The present invention is characterized by having a large number of needle-like protrusions on one or both sides of the resin sheet. The term “large” means that there are 10 or more, preferably several tens, and several hundreds or more than several thousands of protrusions. The number of needle-like protrusions mainly depends on the value of W of the present invention, but the present invention can provide a large number of needle-like protrusions because W is smaller than the height H of the protrusions. A large number of needle-like projections means that the compressive strength is large, and a small W and a large H mean that the three-dimensional structure of the present invention is flexible because it means that it is flexible and bulky. However, it was possible to obtain a structure with high compressive strength but high bulk. The needle-like protrusions in the structure of the present invention do not necessarily have a constant pitch, and may have a complicated pitch rather than a random pitch or a simple constant pitch.

  In the present invention, the tip of the needle-like protrusion formed by deforming part of the resin sheet on one or both surfaces of the resin sheet is further deformed, and the deformed tip The thickness of the part can be a structure that is equal to or less than the thickness of the side wall in the 1 / 2H part. If the needle-like protrusion is normally manufactured, the tip of the needle-like protrusion becomes thick as shown in Patent Document 1 of the prior art. However, after the needle-like protrusion is formed by the needle-shaped mold in the present invention, the needle-shaped mold is formed into a tubular body, so that a hot fluid such as heated air is ejected from the inside of the needle-shaped mold. The tip portion of the protrusion is further deformed, and a structure in which a thin molded body is further added to the tip portion can be obtained. By further deformation of the tip portion, the height of the needle-like protrusions was further increased, and a structure with higher bulkiness could be obtained. Furthermore, since the thickness of the tip portion is reduced, it becomes easier to melt the tip portion in order to make a hole in the tip portion, and when other sheet-like material is melted and joined to the tip portion, Melting became easy. It is desirable that the thickness of the front end portion is 1/2 or less of the thickness of the 1 / 2H portion.

  In addition, since the needle-shaped mold of the present invention is formed of a tubular body, after the needle-shaped protrusion is formed by the needle-shaped mold, the tip of the needle-shaped protrusion is further deformed by suction using the tubular body. And it can be set as the solid structure which has a hollow in a front-end | tip part. The structure having a dent at the tip has a high bonding strength with the sheet-like material because the adhesive is well placed and the joining surface becomes large when the sheet-like material is joined with the adhesive at the tip. be able to. In addition, by making the tip of the tubular body into a star shape, a heart shape, or the like, a design having these shapes can be imparted to the depression, and a three-dimensional structure having a design effect can be obtained.

  As another means of using the tubular body for suction, there is a hole at the tip of the needle-like protrusion by breaking the tip of the needle-like protrusion and making a hole at the tip by performing strong suction. It can be a structure. The structure having a hole at the tip of the needle-like protrusion can be realized by means such as the above-described means of further thinning the tip by further deformation, and melting and removing the tip in that state or by breaking through the tip. .

  The three-dimensional structure of the present invention can be a structure joined to a sheet-like object at the tip of the needle-like protrusion. The needle-like projections in the present invention facilitate the fusion bonding by making the tip thin, and conversely, the bonding to the sheet-like material at the tip is very easy by having a recess in the tip. It is easy to use. As an example of the joining method of the three-dimensional structure and the sheet-like material in the present invention, when extruding and laminating a molten resin, or when heat-melting a resin sheet, contact with the tip of the needle-like protrusion of the three-dimensional structure. The tip of the needle-like protrusion can be melted and joined by the heat capacity of the molten resin sheet. Moreover, after applying an adhesive such as a hot-melt adhesive or an emulsion adhesive to the tip of the sheet-like material or three-dimensional structure, it is possible to perform bonding and bonding. By joining with the sheet-like material, the dimensional stability is improved, and the movement of the needle-like projections to the left and right is prevented, so that the compressive strength is also increased. The type of sheet-like material to be joined is not only a resin sheet similar to the sheet for forming the three-dimensional structure of the present invention, but also a material having air permeability and water permeability such as woven fabric, knitted fabric, non-woven fabric, net, paper, etc., heat resistance If required, a metal such as an aluminum foil or a ceramic plate can also be used. In the resin sheet, a perforated film is suitable when air permeability and water permeability are required. A breathable foam sheet can also be used. By joining these air-permeable sheets, it was possible to make a “breathing heat insulating board”, and it was possible to obtain a three-dimensional structure having anti-condensation properties by passing almost no water vapor but passing air. . As a result, it does not tingle like glass wool, and the product can be reused as a resin.

  The present invention is characterized in that an object can be filled into the hollow inside the needle-like protrusion of the present invention by the tubular needle-shaped mold of the present invention. In particular, in the double-sided protrusion structure, it is difficult to fill an object into the protrusion after the three-dimensional structure is formed, but in the present invention, the object can be filled in the process of manufacturing the protrusion. The object has fluidity at the time of filling, but is preferably an object having solidification or strong viscosity by cooling or chemical reaction after filling. In a single-sided structure, an object can be held by joining another sheet-like material to the bottom surface even if it is still fluid after filling. Since the three-dimensional structure of the present invention has thin and high protrusions, the surface area is large, and by utilizing this fact, a fluid is passed between the protrusions using a heat storage material, a heating medium, a cooling medium, or the like. Thereby, it can be set as a heat exchange structure with sufficient heat exchange efficiency, such as a cooling tower.

  As an example of the manufacturing method of the three-dimensional structure of the present invention, many needle-shaped molds are integrated with the substrate with respect to the resin sheet having fluidity due to being higher than the deflection temperature of the resin. When the needle-shaped mold of the substrate moves in the direction perpendicular to the resin sheet, it penetrates into the resin sheet and deforms the resin sheet. And the structure which has a needle-like protrusion on the single side | surface or both surfaces can be manufactured by being cooled or solidified in the state which maintained the state of the deformation | transformation. The deflection temperature under load of the resin is determined by JISK7207 and is also referred to as a heat distortion temperature. At the deflection temperature under load used in the present invention, the bending stress applied to the B method, that is, the test piece is 45.1 N per square centimeter. Above the load deflection temperature of the resin, the resin sheet can be deformed by needle-like protrusions, preferably 30 ° C. or more, more preferably 50 ° C. or more, and most preferably 80 ° C. or more than the load deflection temperature. Deformation is possible even when the deflection temperature under load is not reached, but the transformation takes time and productivity is poor. The softening of the resin sheet is not only a temperature effect, but may be chemically softened by a solvent or a plasticizer, such as a water solvent in polyvinyl alcohol or a plasticizer in a polyvinyl chloride resin. It is a requirement that the resin sheet is at or above the deflection temperature under load.

  In the needle mold for deforming the resin sheet in the production method of the present invention, the height h of the protrusion is preferably 3 mm or more, and the width w at 1/2 of h is preferably h ≧ 3w. The needle-shaped mold is a needle-like elongated shape, and the diameter of the needle may be constant, but may be a tapered shape with a thin tip. This is because, by adopting such a shape, a long and narrow needle-like projection can be realized, and a flexible but pressure-resistant three-dimensional structure of the present invention can be realized. The height h of the needle-shaped mold is 3 mm or more, preferably 200 mm or less, more preferably 5 mm or more and 100 mm or less, and most preferably 8 mm or more and 50 mm or less. If it does not reach 3 mm, the bulkiness of the three-dimensional structure of the present invention cannot be satisfied, and if it exceeds 200 mm, it may be difficult to stably produce the elongated protrusions of the present invention. Further, the width w of the needle-shaped mold at the half height h is h ≧ 3w, preferably h ≦ 100w, more preferably h ≧ 5w, h ≦ 70w, h ≧ 10w. Most preferably, h ≦ 50w. This is because, by making these ranges, the manufactured three-dimensional structure can increase the bulkiness and porosity, and can have a more flexible structure. In addition, when h <3w, the bulkiness as the three-dimensional structure of the present invention cannot be satisfied, and when h> 100w, it may be difficult to stably manufacture the elongated protrusions of the present invention. Because. Note that the needle-shaped mold does not necessarily mean only a cylindrical or conical symmetrical shape, and the cross section at w may have various shapes such as an ellipse, a square, and a triangle. As the value of w in this case, the smallest value in the cross section at 1 / 2h is adopted. In addition, the measurement of h and w is obtained by measuring 30 projections selected at random and arithmetically averaging them.

  Many needle molds of the present invention are integrated with a substrate. The integration may be a case of being integrally machined with the same material, but the needle may be bonded to the substrate by means such as screwing, welding, adhesive bonding, or caulking. The advantage of the thin and long needle-shaped mold according to the present invention is that it is a thin needle-shaped, and both the needle-shaped mold as the device and the needle-shaped projection of the product have a small heat capacity, so the cooling efficiency is good and the productivity is good. is there. Further, in order to improve the compressive strength, not only the shape but also the molecular orientation effect due to the deformation at the time of melting imparted at the time of molding is great. The present invention is also characterized in that the molecular orientation can be increased because the deformation rate is large and the cooling efficiency is also large.

  Many needle-shaped molds of the present invention are constituted by a tubular body, and are characterized in that a fluid such as gas or liquid is guided through a tube inside the tubular body. Thereby, for example, by blowing air, the mold separation from the needle-shaped mold is improved by the wind pressure. In addition, by using the air as cooling air, the cooling of the molded body can be accelerated and the molding speed can be increased. As this fluid, air containing mist such as oil agent or mold release agent, or oil agent, etc. are ejected, so that the needle-like projections of the molded three-dimensional structure can be easily separated from the needle-like mold or perforated presser plate. become. Furthermore, the tubular needle-like protrusions can be used to fill a cavity formed in the protrusions with an object when the protrusions are formed.

  Further, by making the needle-shaped mold into a tubular body in this way, the tip of the needle-shaped protrusion of the three-dimensional structure of the present invention is further deformed by ejecting a fluid from the inside of the tubular body. You can also Thus, when the tip of the needle-like projection is further deformed, the deformation rate is large, so that the thickness can be reduced, and the thickness of the further deformed tip is equal to the thickness of the side wall of the 1 / 2H portion. Projections that are 1/2 or less, preferably 1/3 or less, and most preferably 1/5 or less can be formed. By adding further deformation in this way, the deformation rate can be increased, and since the tip is thin, it can be easily dissolved by heat, solvent, etc., and bonded to other sheet-like materials etc. It became possible to improve the sex. For such deformation, it is desirable that the fluid to be ejected is a heated fluid, and usually heated air is used. However, steam, an oiling agent, a sealing agent, or the like can be used to provide a special function.

  Further, by making the needle-shaped mold into a tubular body and sucking from the inside of the tubular body, the cross-sectional shape of the tip of the needle-shaped protrusion of the three-dimensional structure of the present invention can be variously changed, so that the needle-shaped protrusion It is also possible to adopt a structure in which a hole is formed at the tip of the slab, or a structure in which a concave depression is formed. Such a depression not only gives a certain aesthetic appearance and design, but also has various functions such as holding another object in the portion by having the depression.

  In the manufacture of a three-dimensional structure having a large number of needle-like protrusions on one side of the sheet-like material in the present invention, a perforated pressing plate having holes corresponding to the many needle-like protrusions is provided on the back surface of the resin sheet. When the needle-shaped mold penetrates the resin sheet, the resin sheet is supported from the back side. Then, the resin sheet is deformed to form needle-like protrusions on one side of the sheet by moving in a direction perpendicular to the resin sheet so that the needle-shaped mold is fitted into the hole of the perforated pressing plate. This perforated pressure plate has a function of dynamically supporting the penetrating needle-shaped force from the back surface of the sheet and a function of a shape factor that determines the diameter of the protrusion formed on one surface of the resin sheet. Even when the same needle mold is inserted, the three-dimensional structure having different diameters (W) can be obtained by changing the diameter of the hole of the perforated pressing plate. The entrance of the hole on the resin sheet side of this perforated pressure plate is chamfered to give consideration to prevent scratches during molding, and to release molds such as silicon or fluororesin on the surface or hole. It is desirable that the surface treatment is performed with a releasing agent such as an agent.

  In the manufacture of a three-dimensional structure having a large number of needle-like protrusions on both surfaces of a sheet-like material in the present invention, a large number of needle-shaped molds are integrated with a substrate, and a pair of the substrates are installed facing each other, When the needle-shaped molds of the pair of substrates move in parallel so as to penetrate into the resin sheet, the resin sheet is deformed and a large number of needle-shaped protrusions are formed on both surfaces of the sheet. Another advantage of the thin and long needle-shaped molds in the manufacturing method of the present invention is that when a large number of needle-shaped molds are installed facing each other, the mechanical accuracy between the opposed needle-shaped molds is improved. The experimental results showed that it was unnecessary. That is, when the needle-shaped molds of a pair of substrates move in parallel so as to penetrate into the resin sheet, the needle-shaped molds facing each other are thin and supple. It seems to be because it is penetrated by the sheet.

  Next, means for continuously producing the three-dimensional structure of the present invention will be described. A large number of substrates on which the needle-shaped molds are fixed are fixed on a conveyor A that is continuously connected and circulated. Also, a pair of conveyors B that are paired with the conveyor A are installed facing each other. When manufacturing a structure having needle-like protrusions on one side of the sheet, the conveyor B is provided with a perforated pressing plate. When the needle-shaped mold penetrates the resin sheet, the perforated pressing plate is configured to support the resin sheet from the back side. Moreover, when manufacturing the structure which has a needle-like protrusion on both surfaces of a sheet | seat, the needle-like type | mold similar to the conveyor A is installed in the conveyor B facing each other. Resin heated above the deflection temperature under load is continuously inserted between the pair of continuously circulating conveyors A and B. With respect to the inserted resin sheet, the needle-shaped mold is penetrated through the resin sheet by a mechanism in which the substrate is moved in the vertical direction, and a protrusion is formed on one or both sides of the resin sheet to continuously form a three-dimensional structure. Is formed. In the conventional method in which the resin sheet is directly sandwiched between continuous conveyors, the needles of the present invention are long, so that when the resin sheet is sandwiched, the needles are stuck obliquely and stable molding cannot be performed. The present invention solves this problem by vertically shifting the substrate and the perforated pressing plate with respect to the resin sheet when sandwiched. Various means can be used for the vertical transition of the substrate and the perforated pressing plate. The transition may be performed by shifting only the substrate, or may be performed integrally with the conveyor.

  As an example of a mechanism in which the substrate or the perforated pressing plate moves vertically when the three-dimensional structure of the present invention is continuously manufactured, a caterpillar (or also called a caterpillar) is used as the conveyor, and the guide groove of the substrate or the like is used. It is a means to move perpendicularly | vertically with respect to the inserted resin sheet. As another means, there is a means for pushing up or pushing down only the substrate or the like on the conveyor by a gantry. The details of these means are as exemplified in the section of the best means for carrying out the invention, as well as raising and lowering the substrate using magnetism, and raising and lowering the substrate using negative pressure suction and pressure. You can also

  It is preferable that a pressurized air chamber is provided behind the perforated pressing plate and / or the substrate in the manufacture of the three-dimensional structure in the present invention. A pressurized air chamber is a chamber in which gas is maintained in a pressurized state or a negative pressure state. It is preferable that the hole holding plate and the substrate are provided with a hole or a slit for guiding the gas from the compressed air chamber to the resin sheet side on which the needle-like protrusions are formed. However, in the case of a perforated pressing plate, a hole opened at a position corresponding to the needle tip of the needle type can be used as it is. The gas is usually air, but if you want to avoid oxidation of the resin, other gases such as nitrogen gas are used, and if you want to humidify the resin sheet, air containing water vapor may be used. is there. First, a case where the compressed air chamber is in a pressurized state and air flows out from the compressed air chamber to the resin sheet side forming the needle-like protrusions will be described. The molded product, perforated presser plate, substrate, etc. are cooled by the air blown to the side of the resin sheet on which the needle-like projections are formed by the pressurized air in the compressed air chamber. Molding speed increases. In addition, due to the air pressure of the compressed air chamber, the air is ejected to the resin sheet side forming the needle-like protrusion, so that the molded resin sheet is stably separated from the perforated pressing plate and the substrate, Also from this aspect, the molding can be performed stably and the molding speed can be increased.

  A release plate having a hole corresponding to the protrusion of the needle-shaped mold on the surface of the substrate is formed between the substrate integrated with the needle-shaped mold in the manufacture of the three-dimensional structure in the present invention and the resin sheet to be molded. It is preferable to be provided. After this mold release plate is molded into a three-dimensional structure with needle-like projections, the mold release plate moves perpendicularly to the direction of the resin sheet, thereby stabilizing the needle-shaped mold and the three-dimensional structure formed. Can be separated and the molding speed can be increased. This release plate is preferably made of a metal such as aluminum, copper, stainless steel or steel. This is because the needle-shaped mold and the molded three-dimensional structure are cooled and stably molded by the heat capacity of the metal release plate, and the molding speed is increased. Since the needle-like projections of the present invention are thin and have a high height, the mold can be stably released when such a release plate moves vertically. In addition to those exemplified in the section of the best means for carrying out the invention, the means for vertical movement of the release plate can be moved up and down by using magnetism, negative pressure suction force or pressure. .

  In addition, the release plate in this invention can also be provided in the other side of a resin sheet seeing from a perforated pressing board. If the tip of the needle-like projection of the three-dimensional structure formed by a needle-shaped mold or the like jumps out to the back of the perforated presser plate, the release plate moves vertically over the tip of the needle-like projection that protrudes. Press it, and conversely push it into the perforated holding plate. In this case, the perforated pressing plate may be a flat plate. Such a release plate on the perforated pressing plate side is particularly effective when the three-dimensional structure of the present invention is a hard resin such as a hard vinyl chloride resin or a polycarbonate resin.

  In manufacturing a structure having needle-like protrusions on one or both sides of the sheet according to the present invention, the following effects can be obtained by making the needle-like mold into a tubular body. The first effect is that production stability and production speed can be increased in the production of needle-like protrusions. In other words, the cooling of the molded body can be accelerated by blowing cooling air from the needle-shaped tubular body. Moreover, the mold separation from the molded body with the needle-shaped mold can be improved by the wind pressure when air is blown, and productivity can be improved. In addition, it becomes easier to release the molded needle-like protrusions from the needle-like mold and the perforated pressing plate by ejecting air containing oil or a mist of a release agent, oil, or the like. These effects can make it possible to produce not only productivity but also thin and long needle-like projections that have been difficult to produce in the past.

  The second effect is that the needle-like projections can be further deformed in the form of the needle-like projections. In other words, hot air is blown from the tubular body constituting the needle-shaped mold, the tip of the sheet is further deformed, the tip is further deformed, the deformation rate of the tip is increased, the tip is thinned, and the adhesiveness is increased. It has the effect of. Also, by sucking from the tubular body, it is possible to make a hole in the tip of the needle-like projection, to give a design effect that gives the tip a certain shape, or to facilitate adhesive bonding with other sheets it can.

  The third effect is that when the needle-shaped mold of the present invention is large and the inner diameter of the tubular body is large, the tip of the molded three-dimensional structure is not in contact with the needle-shaped mold but in contact with air. So cooling is slow. Therefore, since the tip of the molded three-dimensional structure maintains a high temperature, the gas is blown from the inside of the tubular body and further deformation is performed using this fact. Bonding with a sheet-like material can also be performed.

  The fourth effect is that the object can be filled into the inside of the cavity of the needle-like protrusion by utilizing the tubular body. In the present invention, the inside drive can be filled in the manufacturing process of the needle-like protrusion, and particularly in the case of the double-sided protrusion, it is difficult to fill the cavity with the object after the needle-like protrusion is formed. In the present invention, however, filling can be performed during the molding process. A solid structure having various functions could be obtained by filling an object in the cavity of the needle-like protrusion.

  Hereinafter, examples of the present invention will be described based on embodiments shown in the drawings. FIG. 1 is a perspective view of a part of a three-dimensional structure having needle-like protrusions on one side manufactured according to the present invention. The three-dimensional structure 1 has a large number of needle-like protrusions 3a, 3b, 3c,... From the resin sheet 2 toward one side. The needle-like protrusions 3a, 3b, and 3c are arranged at a constant pitch p in the horizontal direction. The needle-like protrusions 3d, 3e, and 3f on the rear side have a constant pitch p in the horizontal direction at a position moved by p / 2 in the lateral direction behind the needle-like protrusions 3a, 3b, and 3c by a p / 2 pitch (pitch q). It is arranged with. Further, the rear needle-like protrusions 3g, 3h, 3i are arranged rearward by a constant pitch p from the row 3a and arranged in the lateral direction at a constant pitch p. That is, the needle-like protrusion 3d is at the center of the square formed by the needle-like protrusions 3a, 3b, 3g, and 3h, and the needle-like protrusion 3e is at the center of the square formed by the needle-like protrusions 3b, 3c, 3h, and 3i. In the case of the double-sided protrusion structure, the protrusions 3d, 3e, and 3f protruded on the back surface side of the resin sheet 2. However, in the single-sided protrusion of the present invention, all protrusions protruded on one side. With respect to, the number of needle-like projections can be increased. However, the arrangement of these needle-like protrusions is a preferable arrangement for providing as many protrusions as possible on the sheet, but is not limited to such an arrangement, and many protrusions are provided on one side of the resin sheet 2. Just go out. The present invention is characterized in that by using a tubular body for the needle-shaped mold, a structure having a thin and high needle-shaped projection as shown in FIG. 1 can be stably manufactured with high productivity.

  FIG. 2 is a perspective view of a part of a three-dimensional structure having needle-like protrusions on both sides manufactured according to the present invention. The three-dimensional structure 11 includes a plurality of needle-like protrusions 13a, 13b, 13c,... Upward from the resin sheet 12, and a plurality of needle-like protrusions 14a, 14b, 14c,. ·have. The upper needle-like protrusions 13a, 13b, and 13c are arranged at a constant pitch p in the horizontal direction, and the rear needle-like protrusions 13d, 13e, and 13f are arranged at a constant pitch p behind the row 13a by a constant pitch p. Are arranged horizontally. The needle-like protrusions 14a, 14b and 14c protruding downward are at a constant pitch in the horizontal direction at a position where the needle-like protrusions 14a, 14b and 14c are moved p / 2 pitches behind the upper needle-like protrusions 13a, 13b and 13c. Arranged by p. The lower rear needle-like protrusions 14d, 14e, and 14f are arranged in the lateral direction at a constant pitch p behind the row 14a and at a constant pitch p. The present invention is characterized in that by using a tubular body for the needle-shaped mold, it is possible to stably manufacture a structure having a thin needle-shaped protrusion and high productivity as shown in FIG.

  FIG. 3 is a cross-sectional view of an example in which the tip of the needle-like protrusion of FIG. 1 is further deformed as seen from the side. Although the case of the single-sided protrusion of FIG. 1 is representative, the same applies to the case of the double-sided protrusion of FIG. An example in which a heated fluid or the like is ejected from the tube inside the needle-shaped mold of the present invention to form further deformed protrusions 21p, 21q, 21r at the tips of the needle-shaped protrusions 3p, 3q, 3r. Shown in the figure. The thickness d1 of the further deformed protrusion 21 is characterized by being thinner than the thickness d2 of the needle-like protrusion 3, particularly the thickness d2 at 1 / 2H (H is the height of the protrusion). The thickness of d1 and d2 is measured by cutting out the portion from the structure and measuring it with a thickness gauge or the like. In the figure, d2 is displayed with a thickness in an oblique direction, but it is a display for making the drawing easy to understand, and is for specifying a place where the thickness is measured. In fact, as described above, the part is cut out, Measure with a thickness meter. The measurement is performed by sampling 10 points at random from the structure for both d1 and d2, and displaying the result as an arithmetic average.

  FIG. 4 shows a cross-sectional view of an example in which the tip of the needle-like projection of FIG. 1 is deformed inward, contrary to the case of FIG. Although the case of the single-sided protrusion of FIG. 1 is representative, the same applies to the case of the double-sided protrusion of FIG. An example of a case where the protrusions 32x, 32y, and 32z are deformed inward at the tips of the needle-like protrusions 3x, 3y, and 3z by suction from the tube inside the needle-shaped mold of the present invention is shown in a side view. It was. And the front-end | tip part was enclosed with the dotted line at the lower part, and it showed as a partially expanded plan view. Further, the deformed protrusion 32x is an example in which a hole is formed by rapid suction. 32y shows the example which gave the hollow. 32z shows an example in which a certain design effect (in this example, a star-shaped design) is given to the depression. In this way, the design of the depression can be realized by making the cross-section of the tip of the needle-shaped tube into this design (star shape).

  FIG. 5 is a side view showing an example in which the object 41 is filled in the cavity inside the needle-like protrusion of the three-dimensional structure 12 of FIG. The three-dimensional structure of the present invention is characterized in that such an object 41 can be enclosed inside the needle-like protrusion, and even a double-sided protrusion structure can be easily made into such a filling substance enclosure type. There is a feature in the point. The object 41 can supply the three-dimensional structure 12 from the tubular body inside the needle-like protrusion in the molding process.

  6 is a cross-sectional view seen from the side showing an example in which a sheet-like object 42 is joined to the tip of the needle-like protrusion of the three-dimensional structure 1 of FIG. Although the case of the single-sided protrusion of FIG. 1 is representative, the same applies to the case of the double-sided protrusion of FIG. By joining the sheet-like material 42, since the three-dimensional structure is compressed, all the needle-like protrusions receive the compressive force equally, so that the compression strength is remarkably improved. Also, regarding the bending strength, the tensile strength and the compressive strength of the sheet-like material 42 resist bending, so that it becomes extremely strong. By using a nonwoven fabric, a net-like material, a perforated film, etc., the sheet-like material 42 can be provided with air permeability and water permeability, and has a function as a filter or a drain material. . By filling the space between the protrusions of these three-dimensional structures with fibrous materials, the functions as a filter, a drain material, and a reaction tank can be further improved. Since the three-dimensional structure 1 of the present invention can make the tip of the projection thin, the tip can be easily melted, and the tip can be made concave so that the adhesive can be easily placed. 6 is easy to manufacture.

  FIG. 7 shows a means for joining a sheet-like material to the three-dimensional structure of the present invention. There are heating rolls 51a, 51b in the traveling direction of the three-dimensional structure 11 having needle-like protrusions 13a, 13b, ..., 14a, 14b, ... on both surfaces of the resin sheet, and the roll 51 has a sheet-like object 52a. , 52b is guided, heated by the heating roll 51, softened, touches the tips of the needle-like projections 13, 14 and is joined to the tips of the needle-like projections 13, 14, and the sheet-like object 52 is joined. The structure 53 is used. In the case where the sheet-like material 52 is a molten resin sheet formed from a T-die, the temperature should have a function of cooling the molten resin. If the sheet-like material 52 changes its properties by heating, such as a microporous film or nonwoven fabric, or if it is difficult to join only by heating, such as a woven fabric or a net, the three-dimensional structure 11 and the sheet-like material 52 Adhesive webs 54 a, 54 b can be guided between them and adhered by the adhesive web 54. When the sheet-like material 52 is characterized by air permeability and water permeability, such as a microporous film and a nonwoven fabric, the adhesive web 54 is not formed in a nonwoven fabric or a net so as not to impair the air permeability. In the case where the adhesive web 54 is less air permeable, it is preferable that the adhesive web 54 is partially disposed in a band shape and joined instead of the entire surface of the sheet-like material 52. . The sheet-like material can be joined by applying an adhesive to the joining surface of the sheet-like material 52 and the tips of the needle-like protrusions 13 and 14 of the three-dimensional structure 11 without using the adhesive web 54. The manufactured three-dimensional structure 53 can be manufactured. Since the three-dimensional structure 11 of the present invention can make the tip of the projection thin, the tip can be easily melted, and the tip can be recessed to make it easier to place the adhesive. It is characterized in that it is easy to manufacture the structure 53 to which the objects 52 are joined.

  FIG. 8 shows an example of a method of manufacturing the three-dimensional structure 1 having needle-like protrusions on one side of the present invention in a cross-sectional view as seen from a part of the side of the apparatus. Needle-shaped dies 63 a, 63 b, and 63 c are provided on the substrate 61, have screw portions 65, and are fixed to the substrate with nuts 66. The acicular dies 63a, 63b, and 63c are only a part of the dies, and the acicular dies are arranged on the plane of the substrate 61 at a constant pitch both in the lateral direction and in the rearward direction of the drawing. A hole holding plate 64 is provided on the substrate 61, and holes 67 corresponding to the positions of the respective protrusions of the needle-shaped mold 63 are formed in the hole holding plate 64. The protrusions of the needle-shaped mold 63 are disposed in the holes 67 by either vertical vertical movement of the plate 64 or both vertical vertical movements. Then, a molten resin sheet 62 having a temperature higher than the deflection temperature under load is introduced between the substrate 61 and the perforated pressing plate 64, and is fitted by the vertical movement of the substrate 61 or the perforated pressing plate 64, or both. Thus, the needle-like protrusions 3a and 3b are formed. In FIG. 8, the perforated plate 64 is shown in the lowest position. In the sheet 2, when a protrusion having a certain area is formed by a single vertical movement stroke of the substrate 61 (or the perforated plate holding plate 64 or both of them), the substrate 61 comes to the lowest position. When the next substrate 61 or the like moves up and down, a needle-like protrusion is formed adjacently and in the next fixed area. In this manner, a three-dimensional structure having a large number of needle-like protrusions is continuously formed by repeating the formation of a certain area by the vertical movement stroke of the substrate 61 and the like. As the vertical stroke of the substrate 61 and the like, vertical movement using an air cylinder or hydraulic cylinder, vertical movement using a cam, vertical movement using a magnetic attractive force or repulsive force, and the like can also be used. In addition, the needle-like protrusions 3 of the present invention need not always have a constant cross section and size on the base, and may be mixed. Further, the molding by the thin and long needle-shaped die 63 of the present invention has a large deformation rate, a large surface area, and a large cooling efficiency, so that the productivity is improved, but in order to further increase the cooling efficiency, the substrate 61 is formed. It is also possible to make holes and introduce cooling air. The air from the substrate 61 can also serve to separate the molded three-dimensional structure 1 from the needle-shaped mold 63. Further, the substrate 61 can be provided with a release plate described later, and the perforated pressing plate 64 can be provided with a compressed air chamber and air holes described later.

  The inside of the needle-shaped mold 63 in FIG. 8 is tubes 68a, 68b, and 68c, and the needle-shaped mold 63 constitutes a tubular body. The pipe 68 is connected to hoses 69a, 69b, and 69c, and is configured so that fluid flows out or sucks from the inside of the pipe in the molding process. By having such a pipe | tube 68, cooling air can be blown in and the cooling rate of a molded article can also be raised, and it can also serve as the role which separates a molded article from the needle-shaped type | mold 63 with an air pressure.

  FIG. 9 shows an example of a method of manufacturing the three-dimensional structure 11 having needle-like protrusions on both sides of the present invention in a cross-sectional view of a part of the apparatus as viewed from the side. Needle-shaped molds 73 a, 73 b, and 73 c are provided on the substrate 71, have screw portions 75, and are fixed to the substrate with nuts 76. The acicular dies 73a, 73b, and 73c are only partly shown, and on the plane of the substrate 71, the acicular dies are arranged at a constant pitch both in the lateral direction and in the rearward direction of the drawing. A plane of the substrate 72 is installed on the upper surface so as to face the plane of the substrate 27, and needle-shaped molds 74a, 74b, and 74c are fixed thereto. Needle-shaped molds 74a, 74b, and 74c are arranged at positions shifted from the needle-shaped mold of substrate 71 by a 1/2 pitch in the horizontal direction and the depth direction. Then, a sheet 62 of molten resin having a temperature higher than the deflection temperature under load is guided between the substrate 71 and the substrate 72, and the substrate 71 is fixed. 73a, 73b, 73c and needle-shaped molds 74a, 74b, 74c move relatively in parallel. By this parallel movement, needle-like protrusions 13a, 13b, 13c, 14a, 14b, and 14c are formed. In FIG. 9, the substrate 71 is at the uppermost position, and the substrate 72 is at the lowermost position. When a protrusion having a certain area is formed by a single vertical movement stroke of the substrate 72, the sheet 62 moves when the substrate 72 reaches the highest position. A needle-like protrusion is formed in the next fixed area adjacently. In this manner, a three-dimensional structure having a large number of needle-like protrusions is continuously formed by repeating the formation of a certain area by the vertical movement stroke of the substrate 72. As the vertical stroke of the substrate 72, vertical movement using an air cylinder or hydraulic cylinder, or vertical movement using a cam can be used. The needle-like protrusions 13 and 14 of the present invention have a high deformation rate, a large surface area, and a high cooling efficiency, so that productivity is improved. However, in order to further improve the cooling efficiency, holes are formed in the substrates 71 and 722. Cooling air can also be introduced. The needle-shaped molds 73a, 73b, and 73c in the present invention have tubes 76a, 76b, and 76c inside to form a tubular body. As a result, a fluid such as air can be fed from the pipe 76 through the hose 77, and suction can be performed. Further, by injecting an object from the tube 76 into the cavity inside the needle-like protrusion of the molded product, the three-dimensional structure filled with the object described in FIG. 5 can be obtained.

  FIG. 10 shows the structure and operation of the compressed air chamber, FIG. A is a plan view, and FIG. B is a sectional view from the side. The hole holding plate 64 has holes 67a, 67b, 67c,... Corresponding to the needle-shaped mold 63, and the hole 67 is indicated by a double ring. Indicates that In addition to the holes 67, a large number of small holes 81 are formed in the perforated pressing plate 64. A pressurized air chamber 82 is provided so as to cover the perforated pressing plate 64 from above. The side wall surrounding the pressure chamber 82 is provided with a seal portion 83 made of fluorine resin, felt, or the like to reduce air leakage due to sliding of the pressure chamber 82 due to the movement of the perforated pressure plate 64. It is. Compressed air is guided to the compressed air chamber 82 by the conduit 85, and the molded three-dimensional structure 84 is removed from the perforated pressure plate 64 by the air pressure of the compressed air from the holes 67 and the small holes 81 of the perforated pressure plate 64. To be released. There is also an effect of cooling the molded three-dimensional structure 84 by the air supplied to the compressed air chamber. In this sense, the degree of sealing of the seal portion 83 does not require strictness. Combining the action of the compressed air chamber 82 and the action of the pipe 76 provided inside the needle-shaped mold 63 can further increase the productivity of the needle-shaped protrusion of the present invention.

  FIG. 11 is a sectional view from the side showing an example in which a release plate 91 and a release plate 92 are provided in the same molding means as in FIGS. The release plate 91 has a hole 93 corresponding to the protrusion of the needle-shaped mold 63 of the substrate 61 between the substrate 61 and the molded three-dimensional structure 84. At the initial stage of molding, the release plate 91 is accommodated in the needle-shaped mold 63 and is lowered to the vicinity of the substrate 61. Then, after the three-dimensional structure 84 is formed, the substrate 61 is lowered as shown in the figure, and the release plate 91 remaining in the position releases the three-dimensional structure 84 from the needle-shaped mold 63. At the same time, the perforated pressing plate 64 is also raised, and the release plate 92 is lowered in the process, and the heads of the needle-like protrusions 3a, 3b, and 3c are pushed down to be separated from the perforated pressing plate 64. The release plate 92 is provided on the opposite side of the perforated presser plate 64 from the resin sheet. After the three-dimensional structure 84 is formed, the release plate 92 moves vertically to the direction of the resin sheet. Then, the tip of the molded three-dimensional structure 84 is pushed down, and the three-dimensional structure is separated from the perforated pressing plate 64. A compressed air chamber 82 can be provided behind the release plate 92, and air is blown out from a small hole 94 formed in the release plate 92 to cool the three-dimensional structure 84 and the perforated pressing plate 64. The perforated pressing plate 64 and the three-dimensional structure 84 can be separated by the air pressure. Further, in the initial process of forming the needle-like protrusion 3 in this figure, a release plate 92 and a pressurized air chamber 82 are provided separately, and the air pressure chamber 82 is sucked under a negative pressure to create a reverse air flow, thereby assisting the forming. The needle-like protrusion 3 and the perforated pressing plate 64 can be cooled. In this figure, the formation of the three-dimensional structure 83 having single-sided needle-like protrusions has been described as an example. However, even in the case of forming a three-dimensional structure having needle-like protrusions on both sides shown in FIG. The template 91 can be used effectively.

Polypropylene (Sun Aroma Co., Ltd., PB370A, MFR1.3, density 0.9 g / cm ³ , deflection temperature under load 80 ° C.) was used as the raw material resin. This resin is extruded from a T die at 225 ° C. and led to the three-dimensional structure molding step shown in FIG. 8 so as to form a 150 μm sheet in a molten state. A molding die having one set of the substrate 61 and the needle-shaped die 63 in FIG. 8 was prepared. The needle-shaped die 63 has a needle diameter of 2.1 mm, a pitch of 8.4 mm, a height of 25 mm, and a tube 68 having an inner diameter of 1.5 mm. A hole 27 (hole diameter 3.5 mmφ, hole chamfering 2 mm on the needle insertion side) of a perforated pressing plate 64 (aluminum, plate thickness 12 mm) is faced to the tip of this one set of molds, and a T die is interposed therebetween. The needle-shaped mold 63 was fitted into the hole 67 of the perforated pressing plate 64 so as to penetrate the resin sheet with the molten resin sheet 2 guided more. The temperature of the molten resin sheet at this time was 218 ° C. Hot air (80 ° C.) was blown into the formed needle-like projection from the inside of the tube 68, and the tip of the needle-like projection could be further deformed as shown in FIG. The height H of the three-dimensional structure when hot air is not blown is 8 mm, the width W at ½ H is 2.7 mm, and the pitch to the protrusion next to the needle-like protrusion is 8.4 mm, ½ part The thickness of the tip was 0.1 mm and the thickness of the tip was 0.15 mm, but by blowing hot air, H was 8.3 mm and the tip was 0.08 mm.

  The three-dimensional structure of the present invention is excellent in pressure resistance in spite of being flexible, and has water permeability and heat insulation in the horizontal direction. Therefore, it is used for buffer sheets, cushion sheets, partitions, flooring and the like.

The perspective view which shows the example of the three-dimensional structure which has a needle-like protrusion on the single side | surface manufactured by this invention. The perspective view which shows the example of the three-dimensional structure which has a needle-like protrusion on both surfaces manufactured by this invention. Sectional drawing seen from the side surface which shows the example of the acicular protrusion in which the front-end | tip part was further deform | transformed by this invention. Sectional drawing seen from the side surface which shows the example of the type | mold formed by deform | transforming inward at the front-end | tip of the acicular protrusion of this invention, and the top view of the part. Sectional drawing seen from the side surface which shows the example in which the object is enclosed in the cavity of the acicular protrusion of the three-dimensional structure of this invention. Sectional drawing which shows the example of the structure where the front-end | tip of the acicular protrusion of the three-dimensional structure of this invention is joined to the sheet-like object. The conceptual diagram which shows the example of the means to join a sheet-like object to the front-end | tip of the three-dimensional structure of this invention. Sectional drawing seen from the side surface of a part of apparatus which manufactures the three-dimensional structure which has a needle-like protrusion on one side by making the needle-shaped type | mold in this invention tubular. Sectional drawing seen from the one part side surface of the apparatus which manufactures the three-dimensional structure which has a needle-like protrusion on both surfaces by making the needle-shaped type | mold in this invention tubular. BRIEF DESCRIPTION OF THE DRAWINGS It is a conceptual diagram of the apparatus which manufactures a needle-shaped protrusion using the compressed air chamber of this invention, A is a top view, B is sectional drawing seen from the side surface. BRIEF DESCRIPTION OF THE DRAWINGS It is a conceptual diagram of the apparatus which manufactures a needle-shaped protrusion using the release plate of this invention, A is a top view, B is sectional drawing seen from the side surface.

Explanation of symbols

1: three-dimensional structure, 2: resin sheet, 3: acicular protrusion.
11: Three-dimensional structure having needle-like protrusions on both sides, 12: Resin sheet,
13: Needle-like protrusions in the upper part, 14: Needle-like protrusions in the lower part.
21p, 21q, 21r: Further deformed protrusions,
32x, 32y, 32z: projections in which the tip of the needle-like projection is deformed inward.
41: Object, 42: Sheet-like material.
51: Heating roller, 52: Sheet-like material,
53: a three-dimensional structure in which a sheet-like material is joined to the tip of a needle-like protrusion;
54: Adhesive web.
61: Substrate, 62: Resin sheet above the softening point, 63: Needle-shaped mold,
64: perforated pressure plate, 65: threaded portion, 66: nut, 67: hole,
68: tube, 69: hose.
71, 72: substrate, 73, 74: needle type, 75: nut,
76: tube, 77: hose.
81: small hole, 82: compressed air chamber, 83: seal part, 84: molded three-dimensional structure.
91, 92: release plate, 93: hole, 94: small hole.

Claims (14)

A large number of protrusions having a height H of 3 mm or more when a part of the resin sheet is deformed on one or both surfaces of the resin sheet, and a width W at 1/2 of H is H ≧ 2W In the three-dimensional structure in which the needle-like protrusions are formed,
A three-dimensional structure characterized in that the tip of the needle-like protrusion is further deformed, and the thickness of the deformed tip is equal to or less than the thickness of the side wall at the 1 / 2H portion. A large number of protrusions having a height H of 3 mm or more when a part of the resin sheet is deformed on one or both surfaces of the resin sheet, and a width W at 1/2 of H is H ≧ 2W In the three-dimensional structure in which the needle-like protrusions are formed,
A three-dimensional structure characterized in that the tip of the needle-like projection is further deformed and has a recess in the deformed tip. A plurality of needle-like protrusions having a height H of 3 mm or more and a width W at 1/2 of H being H ≧ 2W by deforming a part of the resin sheet on both surfaces of the resin sheet In the three-dimensional structure in which is formed,
A three-dimensional structure characterized in that an object is filled in a cavity formed inside the needle-like protrusion.   3. A three-dimensional structure characterized in that a sheet-like material is bonded to the tip of the needle-like protrusion of claim 1 or 2. A plurality of needle-shaped molds are integrated with the substrate on one side of the resin sheet having fluidity when the temperature is higher than the resin deflection temperature, and the other side of the resin sheet is provided. On the side of the surface, a perforated pressing plate that is perforated at a position corresponding to the protrusion of the needle-shaped mold is configured to support the resin sheet from the back when the needle-shaped mold penetrates the resin sheet The resin sheet is deformed by moving in a direction perpendicular to the resin sheet so that the needle mold fits into the hole of the perforated pressure plate, and a large number of sheets are formed on one side of the sheet. In the method of manufacturing a three-dimensional structure in which needle-like protrusions are formed,
The needle-shaped mold is formed of a tubular body, and a fluid flows out or is sucked from the inside of the tube of the tubular body in a process in which the resin sheet is formed into the needle-shaped protrusion. Manufacturing method of structure. For a resin sheet having fluidity that is equal to or higher than the deflection temperature under load of the resin, the height h of the protrusion is 3 mm or more, and the width w at half of h is h ≧ 3w. The needle-shaped mold is integrated with the substrate, and a pair of the substrates are installed facing each other, and the resin sheet is deformed by moving in parallel so that the needle-shaped molds of the pair of substrates penetrate each other into the resin sheet In the method for producing a three-dimensional structure in which a large number of needle-like protrusions are formed on both sides of the sheet,
The needle-shaped mold is formed of a tubular body, and a fluid flows out or is sucked from the inside of the tube of the tubular body in a process in which the resin sheet is formed into the needle-shaped protrusion. Manufacturing method of structure.   The fluid flowing out from the inside of the tube of the tubular body according to claim 5 or 6 is a heated fluid, and further deformed by a jet pressure by the fluid at a tip of the needle-like projection formed by pressing with the tubular body. A method for producing a three-dimensional structure, characterized in that   By suctioning from the inside of the tube of the tubular body according to claim 5 or 6, a hole is opened at the tip of the needle-like projection by suction pressure, or the tip of the needle-like projection is made into a fixed shape. A method for producing a three-dimensional structure, characterized by being shaped.   The method for manufacturing a three-dimensional structure according to claim 5 or 6, wherein the object is filled in the cavity inside the needle-like protrusion by flowing out the fluid from the inside of the tube of the tubular body according to claim 5 or 6. A plurality of needle-shaped molds are integrated with the substrate on one side of the resin sheet having fluidity when the temperature is higher than the resin deflection temperature, and the other side of the resin sheet is provided. On the side of the surface, a perforated pressing plate that is perforated at a position corresponding to the protrusion of the needle-shaped mold is configured to support the resin sheet from the back when the needle-shaped mold penetrates the resin sheet The resin sheet is deformed by moving in a direction perpendicular to the resin sheet so that the needle mold fits into the hole of the perforated pressure plate, and a large number of sheets are formed on one side of the sheet. In the manufacturing apparatus of a three-dimensional structure in which needle-like protrusions are formed,
The needle-shaped mold is composed of a tubular body, and fluid is flown out or sucked from the inside of the tube of the tubular body when the resin sheet is formed into the needle-shaped protrusion. A three-dimensional structure manufacturing apparatus characterized by For a resin sheet having fluidity that is equal to or higher than the deflection temperature under load of the resin, the height h of the protrusion is 3 mm or more, and the width w at half of h is h ≧ 3w. The needle-shaped mold is integrated with the substrate, and a pair of the substrates are installed facing each other, and the resin sheet is deformed by moving in parallel so that the needle-shaped molds of the pair of substrates penetrate each other into the resin sheet In the manufacturing apparatus of a three-dimensional structure in which a large number of needle-like protrusions are formed on both sides of the sheet,
The needle-shaped mold is composed of a tubular body, and fluid is flown out or sucked from the inside of the tube of the tubular body when the resin sheet is formed into the needle-shaped protrusion. A three-dimensional structure manufacturing apparatus characterized by   A release plate having holes at positions corresponding to the protrusions of the needle-shaped mold is provided on the surface of the substrate according to claim 10, and after the three-dimensional structure is molded, the release plate is the resin sheet. The apparatus for manufacturing a three-dimensional structure is configured so that the substrate and the molded three-dimensional structure are separated by moving perpendicularly to the direction of the three-dimensional structure.   A release plate is provided on the opposite side to the resin sheet of the perforated pressing plate in claim 10, and after the three-dimensional structure is molded, the release plate moves perpendicular to the direction of the resin sheet. The three-dimensional structure is manufactured by pressing down the tip portion of the molded three-dimensional structure to separate the three-dimensional structure from the perforated pressing plate. apparatus. A compressed air chamber is provided behind the perforated pressing plate and / or the substrate according to claim 10 or 11, and the resin sheet on which the needle-like protrusions are formed is moved by the air pressure of the compressed air chamber. An apparatus for producing a three-dimensional structure, wherein the apparatus is configured to be separated from a perforated pressure plate and / or the needle-shaped mold.

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