JP3343752B2 - Method for manufacturing fiber slat for blind, continuous molding apparatus, and continuous molding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a fiber slat for a blind, a continuous molding apparatus, and a continuous molding method, and more particularly, to continuously mold a curved fiber slat for a blind. The present invention relates to a method for manufacturing a fiber slat for blinds, an apparatus for continuously molding an object to be formed of a long nonwoven fabric or a knitted woven fabric at least partially containing a thermoplastic resin into a predetermined shape, and a method therefor. .

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 11, a fiber slat for blinds has a male mold 102 provided with a fiber base material X cut to a predetermined width and having a curved shape.
And the female mold 103, and the temperature in the mold 101 is raised from room temperature to 230 ° C., and then cooled to thermally fix the cross-sectional shape of the fiber base material X to a curved surface. Had been manufactured.

However, in the conventional method of manufacturing fiber slats for blinds, since the batch type is used as described above, the operation of setting and removing the fiber base material one by one from the mold and then setting it again is performed. Must be performed,
It was very time-consuming. In addition, since the fiber base material is curved by heat fixing, sufficient heating is required to give shape retention, and the heating time is long.

[0004] Therefore, as a continuous molding method, a method is considered in which a heated object to be processed is cooled while passing between a pair of upper and lower convex rollers and concave rollers to form a predetermined shape.

[0005] However, according to this method, there is a problem in that the object to be processed is subjected to tension (tension) during traveling, and the object to be processed elongates and a width is changed. In addition, there was a problem that bending occurred.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to provide a highly efficient blind capable of continuously forming a curved surface shape of a fiber slat section for a blind. The production method of fiber slats for use, the productivity can be improved by continuous molding,
An object of the present invention is to provide a continuous molding apparatus and a continuous molding method that can prevent elongation, width change, and bending of the object without applying tension to the object during traveling.

[0007]

In order to achieve the above object, the invention according to claim 1 is to provide a heating zone in which a fibrous base material containing a heat-sealing component is heated to make the heat- sealing component plastic.
The belt runs continuously while being transported to the cooling zone by a belt.
And cooling while curving in the cooling zone
Manufacturing method of fiber slats for blinds
And at least two upper and lower metal belts
While sandwiched between members, the cooling zone
Running continuously through the cooling zone and
A method of manufacturing a fiber slat for a blind, characterized in that the method is passed between a pair of upper and lower forming rollers provided by the above method.

The gist of the invention according to claim 2 is a method of manufacturing a fiber slat for a blind in which the fiber base material is a knit.

The gist of the invention according to claim 3 is a method of manufacturing a fiber slat for blinds in which the fiber base material is a woven fabric.

The gist of the invention according to claim 4 is a method of manufacturing a fiber slat for blinds in which the fiber base material is a nonwoven fabric.

The gist of the invention according to claim 5 is a method of manufacturing a fiber slat for blinds, characterized in that the heat fusible component contained in the fiber base material is a heat fusible fiber.

According to a sixth aspect of the present invention, there is provided a method for producing a fiber slat for branding, wherein the heat-sealing component contained in the fiber base is a heat-fusible resin applied to the fiber base. Abstract.

[0013] The gist of the invention according to claim 7 is to provide a method of manufacturing a fiber slat for a brand, characterized in that a fiber base material is passed between male and female rolls provided with curved roller surfaces.

The gist of the invention described in claim 8 is a gist of a method of manufacturing a fiber slat for blinds, wherein the fiber base material is conveyed while being sandwiched between a pair of upper and lower endless belts.

Hereinafter, the method for producing the fiber slat for blinds according to the first to eighth aspects will be described in more detail.

In the method for producing a fiber slat for blinds (hereinafter referred to as a slat production method), a fiber base material containing a heat-sealing component is conveyed by a belt, the fiber base material is heated, and then the fiber base material is heated. Is cooled while being curved. The fibrous base material used in the method for producing a slat of the present invention is obtained by cutting a fibrous material containing a heat-sealing component, such as a knitted fabric, a woven fabric, or a nonwoven fabric, into a predetermined width to provide a belt shape. The heat-sealing component is a thermoplastic resin such as polyester, polyethylene, polypropylene, vinyl chloride, acrylic, and styrene, or a synthetic fiber made of these resins. The fiber material can be contained in the fiber base material by coating and impregnating the fiber material, or by mixing a synthetic fiber made of these resins with a fiber material such as a knitted fabric, a woven fabric, or a nonwoven fabric.

Prior to applying the molding process of the present invention, the fiber material is coated with a flame retardant, a water repellent, an antistatic agent, etc., preheat set, etc., to provide flame retardancy, water repellency, and antistatic properties. For imparting functions such as heat resistance and moisture resistance, processing for imparting functions such as heat resistance and moisture resistance can be performed. Of course, such processing may be performed after the molding.

In the process of transporting the fiber material thus constituted by a belt, the fiber material is heated, curved, and cooled. First, the fiber material cut into a belt shape is transported by a belt. The fiber material is conveyed by placing the fiber material on a belt that moves in a predetermined direction, or as shown in FIG. 1, by moving the fiber material X between a pair of upper and lower endless belts 1 and 2. Can be fixed and transported. The belt to be used is not particularly limited, but as shown in FIG. 2 or FIG. 3, when the fiber material is curved along the roller, the belt has such a softness that no gap is formed between the roller and the roller. Cracks easily even if it is curved,
Those that are not easily damaged are preferred. The conveying speed is optional, but if it is too fast, it causes inconveniences such as insufficient heat fusion of the heat fusion component, cooling and insufficient molding, and conversely, if it is too slow Therefore, the temperature should be determined in relation to the heat-fusing component used, the heating temperature, and the cooling temperature.

Heating can be performed, for example, by flowing endless belts 1 and 2 sandwiching a fiber material X into a heating chamber 8 as shown in FIG. Heating can also be performed by passing a fiber material between heating rollers. The heating temperature is preferably the melting point of the heat sealing component contained in the fiber material, or a temperature higher than the melting point. By heating in this way, the heat fusion component contained in the fiber material is thermally fused. If the heating temperature is too high, the melted heat-fusion component flows out of the fiber base material, or the melted heat-fusion component moves to the lower side of the fiber base material to form a film. May occur.

Next, the fiber substrate is cooled while being curved. For example, as shown in FIGS. 1 and 2, a male roll 4 is disposed in the cooling chamber 6 and has a curved roller surface, and a female roll 5 is provided corresponding to the shape of the roller surface of the male roll 4. By passing the endless belts 1 and 2 sandwiching the fiber base material X between the male and female rolls 3, the endless belts 1 and 2 are cooled and curved along the roll shape of the male and female rolls 3. The fiber base material X sandwiched between the two also curves and cools accordingly. Then, the fiber base material X is molded in a curved state. still,
The one shown in the drawings is one in which the fiber base material is curved and cooled in a state in which the movement of the fiber material is fixed between the pair of upper and lower endless belts, but is not limited thereto. By passing the belt on which the fiber material is placed into the cooling chamber and passing between the male and female rolls arranged in the cooling chamber,
The fiber material can also be curved and cooled.

When the curvature (R) is relatively small,
As shown in FIG. 3, the endless belt 1 sandwiching the fiber base material X,
The fiber base material X is passed through the endless belts 1 and 2 by providing the roller surface in a curved shape and passing the endless belts 1 and 2 while being pulled by rolls 7 arranged above or below the conveying direction of the endless belts 1 and 2. The fiber substrate X can be curved by the tensile force of 2 along the roll shape of the roll 7.

The cooling of the fiber base material is performed by blowing cold air,
In addition to the method of bending the fiber base in a cooling chamber placed in a low-temperature atmosphere, the method can also be performed by using the male and female rolls 3 and the rolls 7 that bend the fiber base as cooling rolls.

The fibrous base material used in the method of the present invention may be cut to a predetermined length, or may be continuous. In this case, a process in which the fiber base material is wound on a roll is processed and then cut into a predetermined length, so that the fiber base material can be easily inserted between the belts, thereby further increasing productivity. Can be.

According to a ninth aspect of the present invention, there is provided a continuous molding apparatus for continuously molding a long nonwoven fabric or a knitted woven fabric containing at least a part of a thermoplastic resin into a predetermined shape. And a heating zone for bringing the resin into a plastic state, a cooling zone arranged behind the heating zone, and a conveying unit for sequentially conveying the object to be processed from the heating zone to the cooling zone, The cooling zone is provided with a pair of upper and lower molding rollers disposed with a gap of a predetermined size, and the transporting means includes at least two upper and lower metal rollers disposed so as to sandwich and transport the workpiece. The workpiece is sandwiched between the metal belt members and is passed between the molding rollers to be molded into a predetermined shape.

According to a tenth aspect of the present invention, there is provided a continuous molding method comprising cooling a workpiece made of a long nonwoven fabric or a knitted woven fabric at least partially containing a thermoplastic resin through a heating zone for making the resin into a plastic state. A continuous molding method in which the object to be processed is continuously run in a zone and is molded into a predetermined shape in the cooling zone, wherein the object to be processed is cooled from the heating zone while being sandwiched between at least two upper and lower metal belt members. The molding method is characterized by continuously traveling in a zone and passing between a pair of upper and lower molding rollers provided in the cooling zone.

The term “the object to be treated containing at least a part of the thermoplastic resin..., The object to be treated” means that the object to be treated may be composed of 100% thermoplastic resin fibers, or This means that a part may contain a thermoplastic resin, and the above-mentioned “when a part contains a thermoplastic resin” means that the thermoplastic resin fiber is converted into another fiber (eg, cotton, hemp, etc.). ) May be mixed or woven or entangled together, or a thermoplastic resin may be coated as a post-process on a workpiece manufactured using fibers other than thermoplastic resin fibers.
This implies that the impregnated object may be used.

When the thermoplastic resin is partially contained, the content of the resin varies depending on the resin to be used, the shape to be molded, and the like.
It is preferably about 10% by weight or more,
It is preferably at least 20% by weight, more preferably at least 30% by weight. If it is less than 10% by weight, it may not be formed into a desired shape, or the shape may be lost. According to the ninth and tenth aspects of the present invention, the object to be processed travels in the heating zone while being sandwiched between at least two upper and lower metal belt members.
In this heating zone, the thermoplastic resin in the object to be processed is in a plastic state, and heads for the cooling zone while maintaining this state.

Then, in the cooling zone, the cooling zone is gradually cooled while passing between a pair of upper and lower forming rollers, and is thereby continuously formed into a predetermined shape.

The productivity is improved by continuously molding the object to be processed, and as described above, the object to be processed travels and is molded while being sandwiched between at least two upper and lower metal belt members. Accordingly, tension is not applied to the object to be processed, and the elongation, the width change, and the curving of the object to be processed can be prevented.

The continuous molding apparatus according to the eleventh aspect is a continuous molding apparatus for continuously molding an object to be formed of a long nonwoven fabric or a knitted woven fabric at least partially containing a thermoplastic resin into a predetermined shape. And a heating zone for bringing the resin into a plastic state, a cooling zone arranged behind the heating zone, and a conveying unit for sequentially conveying the object to be processed from the heating zone to the cooling zone, The cooling zone includes a slow cooling unit for crystallizing the plasticized resin, and a main cooling unit for cooling the crystallized resin. A pair of upper and lower forming rollers arranged with existence are provided,
The transporting means is constituted by at least two upper and lower metal belt members arranged to sandwich and transport the object to be processed, and the molding roller is disposed in a state where the object to be processed is sandwiched between the metal belt members. It is made to pass through and molded into a predetermined shape.

According to a twelfth aspect of the present invention, there is provided a continuous molding method in which a workpiece made of a long nonwoven fabric or a knitted fabric containing at least a part of a thermoplastic resin is continuously moved to a cooling zone via a heating zone. A continuous molding method for molding into a predetermined shape in the cooling zone, wherein the object to be processed is sandwiched between at least two upper and lower metal belt members, and a heating zone for plasticizing the resin is provided. While continuously traveling to a cooling zone constituted by a slow cooling unit for crystallizing the resin in the state and a main cooling unit for cooling the crystallized resin, the upper and lower portions provided in the cooling zone This is a molding method characterized in that the material is passed between a pair of molding rollers.

The meaning of the wording "the object to be treated containing at least a part of the thermoplastic resin ..." means that the object to be treated is made of 100% thermoplastic resin fiber. Alternatively, it means that a part may contain a thermoplastic resin, and the above-mentioned “when a part contains a thermoplastic resin” means that the thermoplastic resin fiber is converted into another fiber (for example, cotton or hemp). To be treated or knitted or entangled together, or to be treated and treated with a thermoplastic resin as a post-process on a treatment object manufactured using fibers other than thermoplastic resin fibers. This means that the object to be processed may be used.

When the thermoplastic resin is partially contained, the content of the resin varies depending on the resin to be used, the shape to be molded, and the like.
It is preferably about 10% by weight or more,
It is preferably at least 20% by weight, more preferably at least 30% by weight. If it is less than 10% by weight, it may not be formed into a desired shape, or the shape may be lost. In the invention according to claims 11 and 12, the object to be processed travels in the heating zone while being sandwiched between at least two metal belt members in the upper and lower directions. In this heating zone, the thermoplastic resin in the object to be processed is in a plastic state, and heads for the cooling zone while maintaining this state.

The cooling zone includes the slow cooling section and the main cooling section as described above. The object to be processed in which the contained resin is in a plastic state first passes through the above-described slow cooling section, and then passes through the main cooling section. While passing through the slow cooling section, the plasticized resin undergoes crystallization, and is cooled in the main cooling section. At the same time, while passing through the slow cooling section and the main cooling section, the workpiece passes between a pair of upper and lower forming rollers provided in the cooling zone and is continuously formed into a predetermined shape.

The productivity is improved by continuously molding the object to be processed, and, as described above, the object to be processed travels and is molded while being sandwiched between at least two metal belt members in the upper and lower directions. Accordingly, tension is not applied to the object to be processed, and the elongation, the width change, and the curving of the object to be processed can be prevented.

Also, the object to be processed can be subjected to an annealing treatment by temporarily passing through a pre-cooling stage instead of cooling the object at once, and the weather resistance of the finally obtained molded article can be improved. The performance is improved. Therefore, the temperature in the slow cooling section and the time required to pass through the slow cooling section (running speed of the object to be treated) are appropriately set (that is, crystallization is sufficient) in accordance with the type of resin, the shape and thickness of the molded product, and the like. Need to be set to the extent that you want to proceed).

[0037]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.

Example 1 Polyester fiber having a melting point of 200 to 210 ° C. (Nuvar 3
0/2, manufactured by Kanebo Co., Ltd.), 358 g / m ² ,
Fine line with 224g / m ^2, cotton basis weight of 134g / m ^2, fabric thickness 1.25mm of Knitting (flex knit, Nishikawa Rose Co., Ltd.), the pre-heat setting for one minute at 160 ℃,
High pressure jet dyeing with flame retardant dye, 140 ° C
Minute drying, water repellent, soil release (SR
Processing), and performing a lower processing such as heat setting at 210 ° C. for 1 minute, and then cutting this into a 25 mm width band.

Next, the knitted fabric (fiber base material X) cut into a predetermined width by the above-mentioned lower processing is subjected to a molding process according to the procedure shown in FIG. First, a knitted fabric is inserted between a pair of upper and lower endless steel belts (belt thickness: 0.08 mm) 1 and 2 and sandwiched and transported. A heating chamber 19 is provided in the belt feeding direction, and four flat rollers 9 are arranged in the heating chamber at intervals in the belt conveyance path. Then, the knitted fabric is passed through the heating chamber 8 while being sandwiched between the pair of steel belts 1 and 2 and passed between the flat rollers 9 (the passing time of the heating chamber is 15 seconds). To heat the knitted fabric and the belts 1 and 2 to a flat state.

Thereafter, the belts 1 and 2 sandwiching the knitted fabric are passed through a cooling chamber 6 in which four male and female rolls 3 each including a male roll 4 and a female roll 5 provided with a curvature of 20R are arranged at intervals. The passage time in the cooling chamber 6 is 15 seconds). And 15
By passing between the male and female rolls 3 while blowing the cold air of ° C., the knitted fabric and the belts 1 and 2 are cooled in a state of being curved along the roll shape. As a result, the knit was shaped in a curved state.

Example 2 Polyester fiber having a melting point of 200 to 210 ° C. (Nuvar 2
0/1, manufactured by Kanebo Co., Ltd.) and 342 g / m ² in weight,
For a woven fabric laid in a plain weave with a vertical density of 34 lines / inch, a horizontal density of 28 lines / inch, and a cloth thickness of 0.75 mm,
The lower processing is performed in the same manner as in Example 1, and the sheet is cut into a width of 25 mm.
Further, a molding process was performed.

The curvature (R) of the slat produced by the above processing was 17.0 (Example 1) and 22.1 (Example 2), respectively. Further, the strength properties of the slats of Example 1 and Example 2 were measured, and the following [Table 1] was obtained.
It was shown to.

[0043]

[Table 1]

From Table 1, it can be seen that the slats of Examples 1 and 2 are warped, twisted, bent, bent, and broken when compared with the standard values of the conventional blind slats made of aluminum. It can be seen that the strengths are all within the range of the standard values, and that they have certain strength physical properties as slats. In addition, the slats of Example 1 and Example 2 can reduce the reverberation of the sound, do not hurt the hands during handling, do not cause air blocking at the time of closing, generate a small contact sound at the time of opening and closing operation, and generate radio interference. It has characteristics such as difficulty.

Embodiment 3 Hereinafter, another embodiment will be described with reference to the drawings. In the present embodiment, a device for continuously molding a blind slat will be described. However, the present invention is not limited to this. Can also be used for

FIG. 4 is an overall side view of the continuous molding apparatus (A). On the right side of the figure, a tape-shaped workpiece (T) is wound around a reel (10). The object to be treated (T) is obtained by mixing and weaving thermoplastic resin fibers such as polypropylene fiber and polyethylene fiber together.

Behind the reel (10) around which the workpiece (T) is wound (left side in FIG. 4), a heating zone (12)
Cooling zones (14) are sequentially arranged.

A front upper roller (16) is disposed in front of the heating zone (12), and a front lower roller (18) is disposed immediately below the roller (16). In addition, behind the cooling zone (14), the front upper roller (1
The rear upper roller (20), which forms a pair with 6), is provided.
Immediately below the roller (20), a rear lower roller (22) paired with the front lower roller (18) is arranged.

An upper conveying means (24) is wound around the front and rear upper rollers (16) and (20), and a lower conveying means (26) is wound around the front and rear lower rollers (18) and (22). ing. The upper conveying means (24) and the lower conveying means (2
6) Both consist of stainless steel belts.

The front upper roller (16) and the front lower roller (18) rotate in the opposite directions, and the rear upper roller (20) and the rear lower roller (22) rotate in opposite directions (see arrows in FIG. 4). . As a result, the front roller (16) (1
8), the two transporting means (24) and (26) travel rearward in contact with each other, and form a heating zone (1).
Through 2), it reaches the cooling zone (14). After exiting the cooling zone (14) and passing through the rear rollers (20) and (22), the vehicle travels forward with a distance from each other.

The workpiece (T) unwound from the reel (10) is sandwiched between the upper transport means (24) and the lower transport means (26), and is held between the two transport means (24).
(26) travels toward the entrance (12a) of the heating zone (12) as each travels (see FIG. 5), and the workpiece (T) sequentially moves from the reel (10) along with this travel. It is unwound. In the heating zone (12), pressing rollers (28) are provided at predetermined intervals so as to sandwich the traveling path of the workpiece (T). This allows the heating zone (1
In 2), it is possible to more effectively prevent the upper and lower transport means (24) and (26) from being separated from the three objects to be processed (T).

As described above, the object to be processed (T) travels in the heating zone (12) while being sandwiched between the upper and lower conveying means (24) and (26). Heated. In the heating zone (12), hot air blowing ducts (30) and (30) for blowing hot air (for example, about 200 ° C.) onto the upper surface and the lower surface of the traveling processing object (T) are provided. It is provided above and below the travel path of (T).

In this heating zone (12), the thermoplastic resin contained in the object to be processed (T) is in a plastic state, and while maintaining this state, the upper and lower conveying means (24) (26)
Heads to the cooling zone (14) while being sandwiched between them.

In the cooling zone (14), as shown in FIGS. 6 to 8, only a small amount of the workpiece (T) sandwiched between the upper and lower transport means (24) and (26) can travel. Gap (K)
And a pair of upper and lower forming rollers (32) arranged in a manner to provide the same.

The above-mentioned forming roller (32) is composed of an upper forming roller (34) and a lower forming roller (36). The upper forming roller (34) has a columnar shape and gradually moves toward the center in the width direction. It has a small diameter.
The lower forming roller (36) is the upper forming roller (34).
Is a column shape having a peripheral surface corresponding to the curved peripheral surface, and has an egg shape (rugby ball type) whose diameter gradually increases toward the center in the width direction.

The upper forming roller (34) and / or the lower forming roller (36) may be positively rotated by a driving means such as a motor (in this case, the conveying means (24)
The traveling speed of (26) and the peripheral speed of the molding roller (32) are the same), and a free roller type that rotates following the traveling upper and lower transport means (24) and (26) may be used. .

A large number of the pair of upper and lower molding rollers (32) are arranged in the front-rear direction in the cooling zone (14), thereby forming a molding roller row (40). The forming roller row (40) is connected to the exit (12b) of the heating zone (12) immediately before the exit (12b) of the heating zone (12).
b) and the inlet (14a) of the cooling zone (14) to the outlet (14b) of the cooling zone (14) (see FIG. 4).

Above and below the above-mentioned forming roller row (40), a cool air blowing duct (42) is provided. As a result, the object to be processed (T) traveling backward while being sandwiched between the upper and lower transport means (24) and (26) receives cold air (for example, 20 ° C.) from the upper and lower surfaces, that is, gradually cools down. While passing between the forming rollers (32), gradually forming a predetermined shape (in the case of the present embodiment, an arc-shaped cross section)
It is molded into.

It is preferable that the distance between one forming roller (32) and another adjacent forming roller (32) is as small as possible. That is, by reducing the interval, the distance between the molding rollers (32) (the molding rollers (32)
(A part without the mark), the conveying means (24) and (26) can maintain the arc shape, that is, the shape corresponding to the forming roller.
Further, by disposing a large number of molding rollers, the processing speed (the traveling speed of the conveying means) can be increased, and the processing time can be shortened.

The object to be processed (T) molded into a predetermined shape is
Still further, it is sent out from the outlet (14b) of the cooling zone (14) while being sandwiched by the upper and lower transfer means (24) and (26).
Thereafter, as described above, the upper and lower transport means (24) (26) are moved by the upper roller (20) and the lower roller (22) on the rear side.
Change their directions, and the object to be processed (T) separates from the transporting means (24) and (26) and continuously travels backward. Then, as shown in FIG. 9, the cutter is cut into predetermined dimensions by a cutter (44) that moves intermittently in the vertical direction.

According to the above-mentioned apparatus (A), the object to be treated (T) can be continuously molded, so that the productivity is dramatically improved. )
Is molded while traveling between two upper and lower stainless steel belts, so that tension is not applied to the object (T), and the elongation, width change, and curving of the object (T) Can be prevented.

In this embodiment, a molded product having an arcuate (R-shaped) vertical cross section was manufactured. However, the present invention is not limited to this, and the shape of the molding roller (32) is changed so that Molded products such as U-shaped, V-shaped, W-shaped, and N-shaped can also be manufactured.

Further, as a heating method in the heating zone (12), a method of injecting hot air is employed, but the invention is not limited thereto, and an infrared radiation heating method may be used.

As a cooling method in the cooling zone (14), a cold air blowing method is employed, but the cooling method is not limited to this and may be a cooling water injection method. Alternatively, the workpiece (T) can be cooled by configuring at least one of the pair of upper and lower forming rolls (32) as a cooling roller.

Embodiment 4 FIG. 10 is an overall side view of a continuous molding apparatus (A '). On the right side of the figure, a tape-shaped workpiece (T) is wound around a reel (10). The object to be treated (T) is obtained by mixing and weaving thermoplastic resin fibers such as polypropylene fiber and polyethylene fiber together.

The heating zone (1) is located behind (to the left in FIG. 10) the reel (10) around which the object (T) is wound.
2), a cooling zone (14) is sequentially arranged.

A front upper roller (16) is disposed in front of the heating zone (12), and a front lower roller (18) is disposed immediately below the roller (16). In addition, behind the cooling zone (14), the front upper roller (1
The rear upper roller (20), which forms a pair with 6), is provided.
Immediately below the roller (20), a rear lower roller (22) paired with the front lower roller (18) is arranged.

The upper transport means (24) is wound around the front and rear upper rollers (16) and (20), and the lower transport means (26) is wound around the front and rear lower rollers (18) and (22). ing. The upper conveying means (24) and the lower conveying means (2
6) Both consist of stainless steel belts.

The front upper roller (16) and the front lower roller (18) rotate in the opposite directions, and the rear upper roller (20) and the rear lower roller (22) rotate in opposite directions (see arrows in FIG. 10). . This allows the front roller (16)
The two transporting means (24) and (26) that have passed through (18) travel rearward in contact with each other, and reach the cooling zone (14) via the heating zone (12). After exiting the cooling zone (14) and passing through the rear rollers (20) and (22), the vehicle travels forward with a distance from each other. Workpiece (T) unwound from the above-mentioned reel (10)
Is located between the upper transport means (24) and the lower transport means (26), and as the two transport means (24) and (26) travel, respectively, the entrance (12a) of the heating zone (12) (See FIG. 5), and the workpiece (T) is sequentially unwound from the reel (10) with this travel.
In the heating zone (12), pressing rollers (28) are provided at predetermined intervals so as to sandwich the traveling path of the workpiece (T). Thereby, in the heating zone (12), it is possible to more effectively prevent the upper and lower conveying means (24) and (26) from being separated from the three objects to be processed (T).

As described above, the object to be processed (T) travels in the heating zone (12) while being sandwiched between the upper and lower conveying means (24) and (26). Heated. In the heating zone (12), hot air blowing ducts (30) and (30) for blowing hot air (for example, wind at about 200 ° C.) onto the upper surface and the lower surface of the traveling object (T) are provided. It is provided above and below the traveling path of the object (T).

In the heating zone (12), the thermoplastic resin contained in the object to be processed (T) is in a plastic state, and while maintaining this state, the upper and lower conveying means (24) (26)
Heads to the cooling zone (14) while being sandwiched between them.

The cooling zone (14) comprises a slow cooling section (15) constituting the front side and a main cooling section (17) constituting the rear side.

The cooling zone (14) is arranged with a small gap (K) that allows the object (T) sandwiched between the upper and lower transport means (24) and (26) to travel. A pair of upper and lower forming rollers (32) are provided (see FIGS. 6 to 8).

The above-mentioned forming roller (32) is composed of an upper forming roller (34) and a lower forming roller (36) each having a symmetrical shape. The upper forming roller (34) has a cylindrical shape and a width. The shape gradually decreases in diameter toward the center in the direction. In addition, lower molding roller (36)
Is a cylindrical shape having a peripheral surface corresponding to the curved peripheral surface of the upper forming roller (34), and has an egg-shaped (rugby ball type) shape whose diameter gradually increases toward the center in the width direction.

The upper forming roller (34) and / or the lower forming roller (36) may be positively rotated by a driving means such as a motor (in this case, the conveying means (24)
The traveling speed of (26) and the peripheral speed of the molding roller (32) are the same), and a free roller type that rotates following the traveling upper and lower transport means (24) and (26) may be used. .

A large number of the pair of upper and lower forming rollers (32) are arranged in the front-rear direction in the cooling zone (14), thereby forming a forming roller row (40). In addition,
The forming roller row (40) is provided with the heating zone (12)
From the heating zone (12) immediately before the exit (12b)
b) and the inlet (14a) of the cooling zone (14) to the outlet (14b) of the cooling zone (14) (FIG. 10).
reference).

The forming roller row (4) in the slow cooling section (15)
Above and below (0), a plurality of pre-cooling ducts (41) are provided (in the present embodiment, five at each of the upper and lower sides). , 150-180 ° C.) is sprayed on both the front and back surfaces of the object (T) (the time required for the object to pass through the slow cooling unit (15) is, for example, 20 to 9
0 seconds).

A cooling air blowing duct (42) is provided above and below the forming roller row (40) in the main cooling section (17). (A wind of 20 ° C.) is sprayed on both the front and back surfaces of the object.

Thus, the upper and lower transport means (24) (26)
After passing through the heating zone (12), the workpiece (T) traveling rearward while being sandwiched between the rollers passes through the molding rollers (32) while being gradually cooled, and gradually has a predetermined shape (this embodiment). In the case of the example, it is molded into an arc-shaped section. The resin in the object to be plasticized in the heating zone is not cooled at once, but is once pre-cooled in the slow cooling unit (15) as described above. At this time,
That is, during pre-cooling, an annealing process is performed on the object (T), and crystallization of the resin in the object (T) proceeds. It is presumed that this is the reason why a molded product having excellent weather resistance is finally obtained. Therefore, the blowing temperature from the pre-cooling duct (41) in the slow cooling unit (15) and the time required to pass through the slow cooling unit (15) (running speed of the object to be treated) depend on the type of resin and the shape of the molded product. It must be set appropriately (ie, so that crystallization proceeds sufficiently) depending on the thickness and thickness.

It is preferable that the distance between one forming roller (32) and another adjacent forming roller (32) is as small as possible. That is, by reducing the distance, the conveying means (24) and (26) can maintain an arc shape even between the forming rollers (32) (where there is no forming roller (32)),
That is, the shape corresponding to the molding roller can be maintained. Also,
By arranging a large number of molding rollers, the processing speed (the traveling speed of the conveying means) can be increased, and the processing time can be shortened.

The object to be processed (T) molded into a predetermined shape is
Still further, it is sent out from the outlet (14b) of the cooling zone (14) while being sandwiched by the upper and lower transfer means (24) and (26).
Thereafter, as described above, the upper and lower transport means (24) (26) are moved by the upper roller (20) and the lower roller (22) on the rear side.
Change their directions, and the object to be processed (T) separates from the transporting means (24) and (26) and continuously travels backward. Then, it is cut into predetermined dimensions by a cutter (44) that moves intermittently in the vertical direction (see FIG. 9).

According to the apparatus (A ′) of the present invention, the object to be processed (T) can be continuously molded, so that the productivity is dramatically improved. (T)
Is molded while traveling between two upper and lower stainless steel belts, so that tension is not applied to the object (T), and the elongation, width change, and curving of the object (T) Can be prevented.

In this embodiment, a molded product having an arcuate (R-shaped) vertical cross section was manufactured. However, the present invention is not limited to this, and the shape of the molding roller (32) is changed so that Molded products such as U-shaped, V-shaped, W-shaped, and N-shaped can also be manufactured.

As the heating method in the heating zone (12), a method of injecting hot air is employed, but the invention is not limited to this, and an infrared radiation heating method may be used.

As a cooling method in the cooling zone (14), a cold air blowing method is adopted, but not limited thereto, a cooling water injection method may be used. Alternatively, the workpiece (T) can be cooled by configuring at least one of the pair of upper and lower forming rolls (32) as a cooling roller.

[0086]

According to the present invention, the above-mentioned structure is provided.
The method for producing a slat according to the above method is characterized in that the fiber base material is heated in a process of transporting the fiber material containing the heat fusion component by a belt to thermally melt the heat fusion component contained in the fiber base material, and then the fiber base Since the material was cooled while being curved, it was possible to continuously mold the curved surface shape of the slat cross section,
Highly efficient fiber slats for blinds can be manufactured.

The slat manufacturing method according to the second aspect uses a knitted fabric as a fiber base material. In this case, the slat has superior strength physical properties such as warpage, twisting and bending as compared with conventional aluminum slats. You can get slats.

The slat manufacturing method according to the third aspect uses a woven fabric as the fiber base material. In this case, the slat has superior strength properties such as warpage, twisting and bending as compared with conventional aluminum slats. You can get slats.

The slat manufacturing method according to claim 4 uses a non-woven fabric as a fiber base material. In this case, the slat has superior strength physical properties such as warpage, twisting and bending as compared with conventional aluminum slats. You can get slats.

In the method for producing a slat according to the fifth aspect, since the heat-fusible fiber is used as the heat-fusing component contained in the fiber base material, the heat-sealable fiber is bonded to the fiber base material in the manufacturing process of the fiber base material. The components can be included without the need for a separate step to include the heat sealing components.

In the method for producing a slat according to the sixth aspect, a fiber base material coated with a heat-fusible resin and containing a heat-sealing component is used. Are uniformly dispersed, and slats having uniform strength and physical properties can be obtained.

In the slat manufacturing method according to the seventh aspect, since the fiber base is curved by passing the fiber base between the fiber rolls having the roller surface formed in a curved shape, the curved shape of the male and female rolls is appropriately adjusted. By changing it, it is possible to freely and accurately mold the curvature R from large to small.

In the slat manufacturing method according to the eighth aspect, the fiber material is conveyed in a state where the fiber material is sandwiched between a pair of upper and lower endless belts and the movement thereof is fixed. The fiber material adheres tightly to the curved surface without any gap, and the fiber material can be accurately curved.

According to the ninth and tenth aspects of the invention, the object to be processed can be continuously molded, so that the productivity is dramatically improved.

Further, since the object to be processed runs and is molded while being sandwiched between at least two metal belt members in the upper and lower directions, no tension is applied to the object to be processed, and the elongation and the width of the object to be processed are prevented. Changes and curving can be prevented.

According to the eleventh and twelfth aspects of the present invention,
Since the object to be processed can be continuously molded, productivity is dramatically improved.

Further, since the object to be processed runs and is molded while being sandwiched between at least two metal belt members in the upper and lower directions, no tension is applied to the object to be processed, and the elongation and the width of the object to be processed are prevented. Changes and curving can be prevented.

Further, the object to be processed is not preliminarily cooled at once, but is preliminarily cooled, so that the object to be processed can be given an annealing effect and the crystallization of the resin can be advanced. The physical properties of the obtained molded article, especially the weather resistance, are improved.

[Brief description of the drawings]

FIG. 1 is a schematic view showing an embodiment of an apparatus used for a slat manufacturing method of the present invention.

FIG. 2 is a front view showing male and female rolls for bending an endless belt.

FIG. 3 is a perspective view showing a state in which an endless belt is pulled by a roll provided in a curved shape.

FIG. 4 is an overall side view of a continuous molding apparatus according to a third embodiment.

FIG. 5 is a partially enlarged side view of the previous figure.

FIG. 6 is a front view of a pair of upper and lower forming rollers.

FIG. 7 is a schematic explanatory view showing a state of being formed by a forming roller.

FIG. 8 is a schematic explanatory view showing a state in which an object to be processed sandwiched between upper and lower conveying means passes between molding rollers.

FIG. 9 is a perspective view showing a state where a molded object to be processed is cut at predetermined intervals.

FIG. 10 is an overall side view of a continuous molding apparatus according to a fourth embodiment.

FIG. 11 is a schematic view showing a mold used in a conventional slat manufacturing method.

[Explanation of symbols]

 A, A ': Continuous molding apparatus T: Workpiece X: Fiber base 1, 2, Endless belt 3: Male / female roll 4: Male roll 5: Female roll 12: Heating zone 12a ... (in the heating zone) inlet 12b ... (in the heating zone) outlet 14 ... ... cooling zone 14a ... (in the cooling zone) inlet 14b ... ... (in the cooling zone) 15 ... slow cooling section 17 ... book Cooling unit 24 Upper conveying means 26 Lower conveying means 30 Hot air blow-out duct 34 Upper forming roller 36 Lower forming roller 40 Forming roller train 41 Pre-cooling duct 42 Cold air blowing duct

──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Kazuhiko Yamamoto One in 101, Kawai-cho, Kawai-cho, Kitatsukatsugi-gun, Nara Prefecture Inside Hirano Tecseed Co., Ltd. (72) Inventor, Norio Morii 101, Kawai-cho, Kawai-cho, Kitakatsuragi-gun, Nara Prefecture, Japan 101-1 Hirano-Techseed Co., Ltd. 56) References JP-A-6-175228 (JP, A) JP-A-53-117238 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) E06B 9/386

Claims (12)

(57) [Claims] 1. A fiber substrate containing a heat-sealing component is heat-sealed.
After passing through the heating zone to make the components plastic
The cooling zone is transported continuously while
Brine that cools and shapes into a predetermined shape while curving at
A method for producing a fiber slat for use in fabricating, wherein the fiber base material comprises at least two upper and lower metal belt members.
From the heating zone to the cooling zone
Run continuously and set in the cooling zone.
Manufacturing method of the blind fabric slats, characterized in Rukoto passed between molding rollers forming the vignetting upper and lower pair. 2. The method according to claim 1, wherein the fiber base is a knit. 3. The method according to claim 1, wherein said fiber base material is a woven fabric. 4. The method according to claim 1, wherein said fibrous base material is a nonwoven fabric. 5. The method according to claim 1, wherein the heat-fusible component contained in the fiber base material is a heat-fusible fiber. 6. The method according to claim 1, wherein the heat-fusible component contained in the fiber base is a heat-fusible resin applied to the fiber base. 7. The method according to claim 1, wherein said fiber base material is passed between male and female rolls having roller surfaces provided in a curved shape. 8. The method according to claim 1, wherein the fiber base material is conveyed while being sandwiched between a pair of upper and lower endless belts. 9. A continuous molding apparatus for continuously molding an object to be processed made of a long nonwoven fabric or a knitted woven fabric at least partially containing a thermoplastic resin into a predetermined shape, wherein the resin is plasticized. A heating zone to be brought into a state, a cooling zone arranged behind the heating zone, and a transport unit for sequentially transporting the workpiece from the heating zone to the cooling zone, wherein the cooling zone has a predetermined size. A pair of upper and lower molding rollers disposed with a gap therebetween, and the transporting means is constituted by at least two upper and lower metal belt members arranged to sandwich and transport the object to be processed, A continuous molding apparatus wherein the object to be processed is passed between the molding rollers while being sandwiched between the metal belt members, and molded into a predetermined shape. 10. An object to be processed comprising a long nonwoven fabric or a knitted woven fabric containing at least a part of a thermoplastic resin is continuously moved to a cooling zone via a heating zone for making the resin plastic. A continuous molding method for molding into a predetermined shape in the cooling zone, wherein the workpiece is continuously moved from the heating zone to the cooling zone while being sandwiched between at least two metal belt members. A continuous molding method characterized by passing between a pair of upper and lower molding rollers provided in the cooling zone. 11. A continuous molding apparatus for continuously molding a long nonwoven fabric or a knitted woven fabric at least partially containing a thermoplastic resin into a predetermined shape, comprising: A heating zone to be brought into a state, a cooling zone arranged behind the heating zone, and a conveying means for sequentially conveying the object to be processed from the heating zone to the cooling zone, wherein the cooling zone is in a plastic state. The gradual cooling unit for crystallizing the resulting resin, the main cooling unit for cooling the crystallized resin, and the cooling zone,
A pair of upper and lower molding rollers arranged with a gap of a predetermined dimension are provided, and the conveying means is constituted by at least two upper and lower metal belt members arranged to sandwich and convey the object to be processed. A continuous molding apparatus wherein the object to be processed is sandwiched between the metal belt members and passed between the molding rollers to be molded into a predetermined shape. 12. An object to be processed comprising a long nonwoven fabric or a knitted fabric containing at least a part of a thermoplastic resin is continuously run through a heating zone to a cooling zone, and a predetermined shape is formed in the cooling zone. In a continuous molding method, the object to be processed is sandwiched between at least two upper and lower metal belt members, and the resin in a plastic state is crystallized from a heating zone in which the resin is in a plastic state. While continuously traveling to the cooling zone constituted by the slow cooling section for cooling and the main cooling section for cooling the crystallized resin, it passes between a pair of upper and lower molding rollers provided in the cooling zone. A continuous molding method characterized by being performed.