JP3636310B2 - Method for forming multi-hole hard cotton molding - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of molding a multi-hole Katawata moldings, in particular, to a method of molding a multi-hole Katawata molded body can be used as a cushioning material and a moderate elasticity and good breathability .
[0002]
[Prior art]
Conventionally, urethane foam has been frequently used as a cushioning material used for mattresses, sheets, etc., a sound absorbing material used for soundproof walls, and the like. Since this urethane foam is difficult to recycle and produces toxic gas when incinerated and discarded, Japanese Patent No. 2944833 discloses a polyester fiber and a low-melting polyester composite fiber instead of urethane foam. It has been proposed to use a sheet-like hard cotton mixed and compressed at a predetermined ratio. Since the hard cotton can be recycled, it does not need to be disposed of, and has excellent properties such as good air permeability. Therefore, the use of the hard cotton is expected as a material to replace urethane foam against the background of the demand for environmental protection.
[0003]
[Problems to be solved by the invention]
However, in conventional hard cotton, air permeability is maintained by the gaps between the fibers formed in the entire area of the hard cotton, so when a heavy article is placed and the hard cotton is compressed, the fibers in that portion The gap between them becomes clogged and the air permeability becomes worse. When such hard cotton is used for a mattress, a sheet or the like, there is a problem that a part supporting the weight is easily peeled off. On the other hand, even when a heavy object is placed, if an attempt is made to secure a gap between the fibers, it becomes hard hard cotton that is difficult to shrink. A mattress or sheet using hard hard cotton has a problem that sufficient elasticity cannot be obtained.
[0004]
The present invention has been made to solve the above problems, the present invention relates molding method multiwell Katawata molded body can be used as a cushioning material and a moderate elasticity and good breathability is there.
[0005]
[0006]
[0007]
[Means for Solving the Problems]
In order to achieve this object, a method for forming a multi-holed cotton-molded article according to claim 1 is a method in which a hot-melt synthetic fiber that is melted by heat treatment is compressed into a flat plate shape, laminated, and then heated and cooled to harden it. A hard cotton sheet forming process for forming a cotton sheet, a cutting process for making a large number of cuts in a staggered pattern from one surface of the hard cotton sheet formed by the hard cotton sheet forming process to the other surface on the opposite side, and A hot-melt process in which the hard cotton sheet that has been cut by the cutting process is stretched, and the constituent material of the hard-cotton sheet is melted by heating the hard cotton sheet with the cut widened, and after the heat-melting process A cooling and solidifying step of cooling the hard cotton sheet and solidifying the constituent material of the hard cotton sheet to form a multi-hole hard cotton molding.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a perspective view of a multi-hole hard cotton molding 1 of the present invention. In FIG. 1, only a part of the multi-hole hard cotton molding 1 is illustrated.
[0009]
The multi-hole hard cotton molding 1 is used as a cushioning material such as a mattress or a sheet, and has an appropriate elasticity to support an object and good air permeability. The multi-hole hard cotton molded body 1 is formed in a flat plate shape and includes a number of holes 2 penetrating from one surface to the other surface on the opposite side. A large number of holes 2 are arranged in a staggered pattern, and the outer shape of each hole 2 is formed in a substantially rhombus shape, and a partition separating two adjacent holes is formed in a substantially flat plate shape.
[0010]
Next, a method of forming the multi-hole hard cotton molded body 1 will be described with reference to FIG. FIG. 2 is a plan view showing an outline of the molding method of the multi-hole hard cotton molding 1. First, tow (wisteria) -like polyester fibers (2 to 100 denier, 5 to 10 cm) are mixed with 5 to 40% by weight of core-sheath tow-like polyester composite fibers (2 to 100 denier, 5 to 10 cm). To produce four flat hard cotton sheets. The hardness of each cotton is 10 degrees, 15 degrees, 25 degrees, and 30 degrees (measured with an Asker F type hardness meter manufactured by Kobunshi Keiki Co., Ltd.), and the density ranges from 0.02 to 0.05 g / cm3. To do. The sheath of the polyester composite fiber is a low-melting point copolymer polyester manufactured by pipe-in-pipe or the like by mixing isophthalic acid during polycondensation. Therefore, by laminating flat hard cotton in order from the smallest hardness and passing hot air at 100 to 200 ° C., the sheath of the polyester composite fiber is melted and the polyester fibers are knotted together, and the laminated hard cotton The volume decreases. Thereafter, by cooling the hard cotton whose volume has been reduced, the melted polyester composite fiber is condensed and the hard cotton sheet 3 is formed.
[0011]
The hard cotton sheet 3 is pressed against a hard cotton sheet 3 by pressing a die having a large number of sharp blades in a staggered pattern from one surface to the other surface on the opposite side. As shown in FIG. 2A, a large number of cuts 4 are formed in a staggered pattern. The plurality of cuts 4 may be put one by one with a cutter or the like, or a mold having a plurality of blades may be pushed many times.
[0012]
After putting a large number of cuts 4 into the hard cotton sheet 3, the hard cotton sheet 3 is stretched in a direction perpendicular to the cuts 4. This stretching is performed by fixing one end of the hard cotton sheet 3 and holding and pulling the other end. Then, in the hard cotton sheet 3, a large number of notches 4 are widened to form a large number of substantially rhombic holes 2 as shown in FIG. 2 (b). In this state, the numerous holes 2 formed by stretching the hard cotton sheet 3 are shrunk when the force for pulling the hard cotton sheet 3 is weakened.
[0013]
In a state where the hard cotton sheet 3 is stretched to form a large number of holes 2, hot air at 100 to 200 ° C. is passed through the hard cotton sheet 3 for 10 to 180 seconds. When the hard cotton sheet 3 is heated, the polyester composite fiber of the constituent material constituting the hard cotton sheet 3 is melted, and the shape of the hard cotton sheet 3 becomes unstable. In order to melt the polyester composite fiber, the hard cotton sheet 3 may be heated using a thermostatic bath or the like.
[0014]
After the hot air is stopped, the hard cotton sheet 3 is stretched for 20 to 180 seconds, and then the cold air is allowed to pass uniformly to cool the hard cotton sheet 3 heated by the hot air. This cooling may be performed by leaving the hard cotton sheet 3 at room temperature without using cold air. When the hard cotton sheet 3 is cooled, the polyester composite fibers constituting the hard cotton sheet 3 are condensed, and the shape of the hard cotton sheet 3 is stabilized. The numerous holes 2 formed by stretching the hard cotton sheet 3 do not shrink even if the force pulling the hard cotton sheet 3 is weakened. Therefore, the multi-holed cotton-molded body 1 having a large number of holes 2 drilled in a staggered pattern is formed.
[0015]
The molded multi-holed hard cotton molded body 1 can be used as a cushioning material for mattresses, sheets and the like by cutting into a required size. In addition, the polyester composite fiber is heated and melted again, and then cooled and solidified, thereby laminating the multi-hole hard cotton molded body 1 and the hard cotton sheet 3 or the like, It is also possible to deform into a shape having a curved surface.
[0016]
Next, a usage example of the multi-hole hard cotton molded body 1 will be described. FIG. 3 is a perspective view showing a panel material 11 using the multi-hole cotton-molded product 1, and a part of the outer plate 12 is cut out for easy understanding.
[0017]
The panel material 11 is used as a sound absorbing material for buildings, vehicles, and the like, and is used as a partition for partitioning an office room or the like. The panel material 11 includes a multi-holed hard cotton molded body 1 in which a large number of holes 2 are perforated and an outer surface formed of flat hard cotton on both surfaces of the multi-hole hard cotton molded body 1. The plates 12 and 13 are attached to each other.
[0018]
A large number of holes 2 have openings formed on both surfaces of the multi-holed cotton-molded body 1 closed by the outer plates 12 and 13, and a large number of air chambers are formed inside the panel material 11. With the air chamber, the panel material 11 can be reduced in weight, and a soundproof wall can be provided that reduces the sound passing from one side of the panel material 11 to the opposite side.
[0019]
FIG. 4 is a perspective view showing a part of a vegetation mat 21 using the multi-hole hard cotton molding 1. The vegetation mat 21 is used as a container for gardening, for example, on a rooftop or a veranda. The vegetation mat 21 is formed in a container shape having a large number of holes 2 by attaching a bottom plate 22 to the multi-hole hard cotton molded body 1 and a lower surface of the multi-hole hard cotton molded body 1. A large number of soils 23 are placed in a large number of holes 2, and plants 24 are planted in the soils 23.
[0020]
In the vegetation mat 21, the soil 23 is put into a large number of holes 2 partitioned by the multi-hole hard cotton molded body 1. Therefore, since a small amount of the soil 23 can be thinned out evenly and spread over a wide range, the size of the soil 23 becomes light and the burden on the building can be reduced.
[0021]
In addition, as a hot-melt synthetic fiber of Claim 1 , a core-sheath-type tow-like polyester composite fiber corresponds.
[0022]
The present invention has been described above based on the embodiments. However, the present invention is not limited to the above-described embodiments, and various modifications and changes can be easily made without departing from the spirit of the present invention. Can be inferred.
[0023]
For example, in the present embodiment, as a method for forming the multi-holed hard cotton molded body 1, the hard cotton sheet 3 with a large number of cuts 4 is stretched, heated in a state where the large numbers of cuts 4 are expanded, and then cooled. Thus, the case where a large number of holes 2 are formed has been described. However, a large number of holes 2 may be formed using punching or cutting. In this case, the multi-holed cotton-molded body 1 provided with a large number of holes 2 having a desired shape can be molded. Even if chips are generated by punching or cutting, they can be recycled as hard cotton material or non-woven fabric by loosening them finely.
[0024]
Moreover, although the present Example demonstrated the case where the flat hard cotton sheet 3 was utilized as a shaping | molding method of the multi-hole hard cotton molded object 1, you may shape | mold the hard cotton sheet 3 in strip | belt shape. If the hard cotton sheet 3 formed into a belt shape is used, a step of making a large number of cuts 4 in the hard cotton sheet 3, a step of stretching the hard cotton sheet 3 and heating the wide number of cuts 4 in a widened state, Since the process of cooling the hard cotton sheet 3 performed can be performed continuously, in-process items can be eliminated. In addition, by providing equipment for pulling the hard cotton sheet 3 downstream of the cooling process, it is possible to convey the hard cotton sheet 3 from each process to the next process and to open a large number of notches 4. It can be implemented using equipment. As a result, equipment can be simplified and equipment costs can be reduced.
[0025]
Furthermore, although the present Example demonstrated the case where the polyester fiber and polyester composite fiber which can be recycled were mixed and used as a raw material of the multi-hole hard cotton molded object 1, in the multi-hole hard cotton molded object 1, You may mix another material according to a use. For example, in the case of using the multi-hole hard cotton molded body 1 for the vegetation mat 21 used in a place where it is easy to dry, by mixing cotton with excellent hygroscopicity, Moisture and nutrients necessary for the plant to grow can be stored sufficiently.
[0026]
[0027]
[0028]
【The invention's effect】
According to the molding method of the multi-hole hard cotton molding according to claim 1, after stretching the hard cotton sheet in which a large number of cuts are made in a staggered pattern by a cutting process and heating the expanded cut sheet, Many holes are formed by cooling. Therefore, compared with the case where a large number of holes are formed by removing chips by punching or the like, there is an effect that a multi-holed hard cotton molded body can be formed with a high yield.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a part of a multi-hole hard cotton molding of the present invention.
FIG. 2 is a plan view showing an outline of a method for forming a multi-hole hard cotton molding.
FIG. 3 is a perspective view showing a panel material using a multi-hole hard cotton molding.
FIG. 4 is a perspective view showing a part of a vegetation mat using a multi-hole hard cotton molding.
[Explanation of symbols]
1 Multi-hole hard cotton molding 2 Many holes 3 Hard cotton sheet 4 Many notches

Claims (1)

A hard cotton sheet forming step in which a hot-melt synthetic fiber that is melted by heat treatment is compressed into a flat plate shape and laminated, and then heated and cooled to form a hard cotton sheet;
An incision step in which a large number of incisions are made in a staggered pattern from one surface of the hard cotton sheet formed by the hard cotton sheet forming step to the other surface on the opposite side;
A heating and melting step of stretching the hard cotton sheet that has been cut by the cutting step, heating the hard cotton sheet in a state in which the cut is widened, and melting the constituent material of the hard cotton sheet,
A multi-holed cotton molding characterized by comprising a cooling and solidifying step of cooling the hard-cotton sheet after the heating and melting step and solidifying the constituent materials of the hard-cotton sheet to form a multi-holed hard-cotton molded body Body molding method.

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