JP4132907B2

JP4132907B2 - Method and apparatus for manufacturing upper space filler of container

Info

Publication number: JP4132907B2
Application number: JP2002082588A
Authority: JP
Inventors: 慎次平本; 保行白石; 健司大西; 昌宏由良
Original assignee: Taisei Kako Co Ltd; Shionogi and Co Ltd
Current assignee: Taisei Kako Co Ltd; Shionogi and Co Ltd
Priority date: 2002-03-25
Filing date: 2002-03-25
Publication date: 2008-08-13
Anticipated expiration: 2022-03-25
Also published as: JP2003276754A

Description

【０００１】
【発明の属する技術分野】
本発明は、錠剤などの固形物を収容した容器の上部に生じる空間を充填するための上部空間充填材の製造方法および装置に関する。
【０００２】
【従来の技術】
錠剤やカプセルなどの固形物は、ガラス瓶や合成樹脂の容器に収容して販売されることが多く、容器の運搬中に容器内で収容物が移動したり破損することなどを防止するために、容器の上部空間に充填材を挿入している。
【０００３】
従来は、このような充填材として、合成樹脂フィルムなどを適宜に丸めたものや、容器サイズに合わせて合成樹脂材を成形加工したものが用いられている。
このような充填材は、輸送中の収容物の移動を防止するために付加的に設けられるものであり、加工費を含めた部材価格は極めて低いものが要求される。
【０００４】
【発明が解決しようとする課題】
ところが、樹脂フィルムなどを用いた充填材は、材料価格は安価であるものの開栓時に取り出し難く、その上、丸めたフィルム内に錠剤が入り込んでフィルムの取り出し時に錠剤が飛び出すような不具合があった。
また、樹脂成形品による専用の充填材は、部材価格が高い上に、容器サイズが異なる容器に共用できず、また、容器サイズが同一でも上部空間容積が異なると充分な充填効果が得られないことがあった。
【０００５】
本発明は、前記事情に鑑みて提案されるもので、サイズの異なる容器においても上部空間を効果的に充填可能な上部空間充填材を製造するための新規な製造方法および製造装置を提供することを目的とする。
【０００６】
【課題を解決するための手段】
前記目的を達成するために、本発明者らは次の技術的手段を講じた。
則ち、本発明の上部空間充填材の製造方法は、軸方向一端が閉塞され他端が開放された伸縮性を有する筒状のネットを軸方向全長に渡って柱状の支持体に被せる工程と、ネットの他端部を支持体の径方向外方へ向けて押し広げつつ軸方向一端側へ巻き返すことによりネットの開放端に巻回部を形成する工程と、巻回部を軸方向一端側へ向けて転動させることにより、筒状のネットを軸方向全長に渡って巻き取り、該ネットをほぼ塊状乃至球状に構成する工程とを備えるものである。
【０００７】
ここで、本発明に採用する筒状のネットは、例えば、合成樹脂材を成形加工して製された伸縮性、可撓性を有する筒状のネットが好適である。従って、以下の説明では、このような合成樹脂で製された筒状のネットを用いた構成として述べる。
【０００８】
上記合成樹脂製のネットは、伸縮性、可撓性を有するため、そのままの状態では形状が不安定で巻き上げ加工を施すのは困難であるが、本発明によれば、伸縮性、可撓性を有する筒状のネットを、ネットの定常状態における内径よりも大きい外径を有する支持体に被せることにより、安定した状態に支持して加工性を確保している。
【０００９】
また、巻回部は、ネットの他端部を支持体の径方向外方へ向けて押し広げつつ軸方向一端側へ巻き返して形成される。巻回部を形成すると、巻き返されたネットの他端部はネットの外周部に巻き込むように当接して形状が安定する。そして、形状の安定した巻回部を軸方向一端側へ向けて転動させることにより、ネットを容易に巻き取ることが可能となる。
【００１０】
また、本発明の上部空間充填材の製造装置は、軸方向一端が閉塞され他端が開放された伸縮性を有する筒状のネットが軸方向全長に渡って被せられる柱状の支持体と、該ネットをほぼ塊状乃至球状に巻き上げる巻き上げ手段とを備え、該巻き上げ手段は、ネットの他端部を支持体の径方向外方へ向けて押し広げつつ軸方向一端側へ巻き返すことによりネットの開放端に巻回部を形成すると共に、該巻回部を軸方向一端側へ向けて転動させることにより筒状のネットを塊状乃至球状となるように軸方向全長に渡って巻き取るように構成されている。
【００１１】
かかる製造装置は、上記本発明の製造方法に好適に使用することができ、支持体と巻き上げ手段とを備えることにより、ネットを安定な状態に支持して短時間に効率良く巻き上げることが可能である。
【００１２】
ここで、本発明に用いるネットは、塩化ビニル樹脂やポリオレフィン系樹脂材などの可撓性を有する合成樹脂材を成形加工して製したものが好適である。ポリオレフィン系樹脂の中でも、ポリエチレン樹脂やポリプロピレン樹脂は薬品に対する耐性も高く最適である。合成樹脂製のネットを用いる場合、筒状に成形加工されたネットの軸方向一端を加熱溶着して閉塞したものを用いる。
【００１３】
上記本発明の製造装置において、巻き上げ手段は、支持体の外周部に配設されてネットの開放端を案内する湾曲部を有する巻き上げ部材を備えることができる。該巻き上げ部材の湾曲部は、支持体に対して軸方向に相対移動可能とすることができる。また、支持体に被せられたネットの他端部に当接する位置にある湾曲部を軸方向一端側に相対移動させることにより、巻回部が形成されるようにネットの他端部が湾曲部によって案内されるように構成できる。さらに、湾曲部をネットの他端側から一端側に向けて相対移動させることによって、巻回部が軸方向一端側へ向けて転動するように該巻回部を前記湾曲部により案内する構成とすることができる。
【００１４】
なお、固定した支持体に対して巻き上げ部材を軸方向に移動させる構成、あるいは、固定した巻き上げ部材に対して支持体を軸方向に移動させる構成のいずれの構成も採用することが可能である。
【００１５】
かかる構成によれば、巻き上げ部材の湾曲部によってネットの他端部を案内して巻回部を形成し、形成された巻回部を湾曲部によってネットの一端側に向けて転動させるように案内して短時間に効率良く巻き上げることが可能である。
【００１６】
また、上記本発明の製造装置において、巻き上げ部材は、支持体の外周部に配設された剛性部材からなり、該剛性部材の軸方向一端側の側面が、湾曲部として機能する凹面であり、剛性部材が支持体に対して軸方向に移動することにより湾曲部が軸方向に移動する構成とすることができる。
【００１７】
これによれば、巻き上げ部材を形成する剛性部材を支持体に対してネットの一端側へ向けて相対移動させると、ネットの他端部は剛性部材の湾曲部に沿って支持体の径方向外方へ向けて押し広げられつつ軸方向一端側へ巻き返される。これにより、ネットの他端部に巻回部が形成される。そして、更に剛性部材を移動させると、形成された巻回部は湾曲部によって軸方向一端側へ向けて転動し、ネットを軸方向全長に渡って塊状乃至球状に巻き取ることが可能である。
【００１８】
ここで、本発明者らは本発明の製造装置において、剛性部材の湾曲部の曲率半径および剛性部材の移動速度を種々に変化させて製造試験を行ったところ、湾曲部の曲率半径が５０ｍｍを超えると巻き上げられた充填材の外形寸法が大きくばらつくことが分かった。また、湾曲部の曲率半径が１０ｍｍ未満の場合は、ネットの他端部を充分に巻き返すことができず、巻回部の形成が困難であった。
従って、湾曲部の曲率半径を１０ｍｍ〜５０ｍｍの範囲内に設定することにより、巻き上げた充填材の外形寸法を調節可能である。
【００１９】
また、試験の結果、剛性部材の移動速度の増加に伴って巻き上げた充填材の高さが増大し、逆に、移動速度を低下すると巻き上げた充填材の高さが減少することが判明した。また、剛性部材の移動速度を５０ｍｍ／分〜１２５０ｍｍ／分の範囲に変化させても巻き上げが可能であった。
従って、前記した剛性部材の湾曲部の曲率半径および剛性部材の移動速度を調整することにより、目的の外径寸法および高さを有する充填材を製造することが可能である。
【００２０】
上記巻き上げ部材は柔軟な紐状部材からなるものとすることができる。該紐状部材の一端は支持体の一端部に固定されていてもよい。紐状部材は、支持体と該支持体に被せられたネットとの間で軸方向に沿って他端側に延びることが好ましい。さらに、紐状部材は、ネットの開放端部で折り返されて紐状部材の他端部は軸方向一端側に延び、この折り返し部によって湾曲部が構成されたものとすることができる。そして、紐状部材の他端部を軸方向一端側に引き上げることによって湾曲部が軸方向一端側に移動する構成とすることができる。
【００２１】
なお、固定した支持体に対して紐状部材の他端部を軸方向に移動させる構成、あるいは、他端部を固定した紐状部材に対して支持体を軸方向に移動させる構成のいずれの構成も採用可能である。
【００２２】
かかる構成によれば、紐状部材の折り返し部分で形成される湾曲部によってネットの他端部を案内して巻回部を形成し、形成された巻回部を湾曲部によってネットの軸方向一端側に転動させて効率良く巻き上げることが可能である。
【００２３】
本発明者らは、本発明の製造装置においても、紐状部材の湾曲部の曲率半径および紐状部材の引き上げ速度を種々に変化させて製造試験を行った。試験の結果、湾曲部の曲率半径が略１０ｍｍの状態でネットを巻き上げると、ネットの他端部に巻回部を安定して形成でき、しかも、巻き上げ後の外形寸法がばらつかないことが分かった。
【００２４】
また、試験の結果、紐状部材の引き上げ速度の増加に伴って巻き上げた充填材の高さが増大し、逆に、引き上げ速度を低下すると巻き上げた充填材の高さが減少する結果が得られた。また、湾曲部の移動速度が５０ｍｍ／分〜１２５０ｍｍ／分の範囲で変化させても巻き上げが可能であった。
従って、紐状部材で形成される湾曲部の曲率半径を略１０ｍｍに設定すると共に、紐状部材の引き上げに伴う湾曲部の移動速度を調整することにより、目的の外径および高さを有する充填材を製造可能である。
【００２５】
さらに、上記複数の巻き上げ部材を、支持体の周方向に配設することができる。上記したように、合成樹脂で製されたネットは可撓性、伸縮性を有する。このため、巻き上げ部材の配設数が少ない場合は、巻き上げ部材が配設されない周方向の部位においてネットの他端側が巻き返され難く、ネットの周方向全周に渡って均一な巻回部を形成することが困難である。しかし、本発明によれば、支持体の周方向に複数の巻き上げ部材を配設するので、巻き上げ部材同士の間隔を狭めることができ、ネットの他端側を周方向全周に渡って均一に巻き返して安定して巻回部を形成可能となる。
【００２６】
上記巻き上げ手段は、ネットをその外周側から支持体に押圧固定する押圧部を備えていてもよく、該押圧部は、湾曲部の軸方向移動に応じて軸方向に移動するものであってよい。これによれば、押圧部によってネットの外周部を支持体に向けて押圧することにより、巻き上げ部材の移動によって軸方向一端側へ向かう力がネットに加わった場合でも、ネットが支持体に対してずれることがなく安定した巻き上げ加工が可能となる。
【００２７】
押圧部を設ける位置は、湾曲部の軸方向一端側であって湾曲部の近傍が良い。押圧部が湾曲部から離れすぎると、ネットの有する可撓性によって巻き上げ時に撓みが生じ易く、安定した巻き上げが困難になる。また、押圧部は、支持体の径方向に移動可能な押圧パッドを設けた構成や、押圧ローラを設けた構成など種々の態様を採ることができる。押圧パッドを設ける場合には、湾曲部の所定長さの移動毎に、押圧パッドの位置を順次軸方向一端側へずらせて押圧する構成を採ることができる。また、押圧ローラを設ける場合には、湾曲部の移動に伴って、湾曲部と押圧ローラとの距離を一定に保つように押圧ローラも追随して軸方向一端側へ回転移動させる構成を採ることができる。
【００２８】
ところで、ネットのずれを抑えるためには、合成樹脂製のネットとの間に生じる摩擦力が大きい材質で支持体を形成すれば良い。合成樹脂に対する摩擦力の大きい素材としては、例えば、シリコーンゴムやウレタンゴムが挙げられる。また、これらのゴムは、ロックウェル硬さ試験で示されるＨＲＣ２０〜ＨＲＣ９０の範囲の硬度を有するものが良く、ＨＲＣ５０〜ＨＲＣ６０の硬度範囲が最適である。このような硬度を有するゴム素材を支持体（表面）に展張することにより、合成樹脂製のネットとの間に生じる摩擦力が増大し、押圧部による押圧と相まって支持体に対するネットのずれが確実に防止される。これにより、安定した巻き取り加工を行うことが可能となる。
【００２９】
また、上記支持体は、軸方向一端側の大径部と、軸方向他端側の小径部と、大径部と小径部との間に位置するテーパー部とを有し、支持体に被せられたネットの他端部は小径部外周に位置する構成とすることができる。これによれば、テーパー部に位置するネットは、テーパー部の外周面に沿って軸方向一端側へ広がるように傾斜する。従って、巻き上げ部材によって巻き返されたネットの他端部は、テーパー部を設けない場合に比べて、ネットの外周部位に巻き込むように当接する。これにより、テーパー部を設けない場合に比べて巻回部が安定して形成され、効率の良い巻き上げを行うことが可能となる。
【００３０】
本発明者らは、本発明の製造装置における支持体各部の外径および長さを種々に変化させて製造試験を行った。その結果、ネットを巻き上げ可能な支持体の外径は、ネットの材質、線径あるいは巻回部の直径に応じて異なるが、特に、巻回部の直径の影響が大きい結果を得た。試験の結果、支持体の外径が巻回部の直径の２／５〜４／５の範囲で巻き上げ可能であり、支持体の外径が巻回部の直径の略１／３のときに最も安定した巻き上げが行われることを確認した。
【００３１】
また、安定した巻き上げを行う条件として、ネットを支持体に被せた状態で、ネットの他端側から１００ｍｍまでの範囲は大径部外径の３／５以下の外径に設定するのが良く、テーパー部の長さは８０ｍｍ以上に設定するのが良いことも判明した。
【００３２】
【発明の実施の形態】
以下に、図面を参照して本発明の好適な実施形態を説明する。
（第１実施形態）
図１は本発明の第１実施形態に係る製造装置１を示す斜視図、図２は製造装置１に採用する巻き上げ部材を示す拡大斜視図、図３は本発明の製造方法を製造装置１を用いて行う工程を示す説明図、図４は図３の製造工程における巻回部の形成過程を詳細に示す拡大図、図５は巻き上げ部材の変形例を示す斜視図である。また、図６は製造装置１で製造された上部空間充填材を示す斜視図、図７は図６の上部空間充填材を薬容器に装着した状態を示す断面図である。
【００３３】
ここで、本実施形態の製造装置１を用いて加工するネットＮは、ポリエチレン樹脂材を成形加工して筒状に網材に形成したもので、伸縮性および可撓性を有する。ネットＮの軸方向一端には、図３（ａ）の様に、加熱溶着により閉塞されて閉塞端Ｎａが形成され、軸方向他端は開放されて開放端Ｎｂを形成している。また、ネットＮの定常状態における内径は後述する支持体の外径よりも小さい。
【００３４】
一方、本実施形態の製造装置１は、図１（ａ）の様に、円柱状の支持体１０と巻き上げ手段１１を備えている。
【００３５】
支持体１０は、上部の大径部１０ａと下部の小径部１０ｃと、これらの間に位置するテーパー部１０ｂとを有し、上端部１０ｄは半球形である。
本実施例では、支持体１０のテーパー部１０ｂの長さを８０ｍｍとし、大径部１０ａに対して小径部１０ｃの外径寸法を略２／５としている。支持体１０にネットＮを軸方向全長に渡って被せると、図４（ａ）の様に、ネットＮの開放端Ｎｂは小径部１０ｃの外周部に位置する。そして、ネットの開放端Ｎｂから軸方向一端側（閉塞端Ｎａ側）へ向けて１００ｍｍの部位の支持体１０の外径は、大径部１０ａの略３／５となるようにテーパー部１０ｂおよび小径部１０ｃの外径および長さを調整している。
また、支持体１０の表面にはロックウェル硬度ＨＲＣ２０のウレタンゴム（不図示）を展張してネットＮの滑り止めを図っている。
【００３６】
巻き上げ手段１１は、巻き上げ部材（剛性部材）１２と押圧ローラ（押圧部）１３で構成される。
剛性部材１２は、図２の様に、所定厚さを有する方形材の一部を円弧状に切り欠いた部材であり、切り欠き部位の凹面は湾曲部１２ａとして機能する。また、湾曲部１２ａの端部に位置する湾曲部下縁１２ｂと湾曲部上縁１２ｃは楔状に尖っており、湾曲部下縁１２ｂに隣接する内側面１２ｄは平面である。
この剛性部材１２は、内側面１２ｄが支持体１０の外周面に近接するように、則ち、剛性部材１２の軸方向一端側の内側面１２に湾曲部１２ａが位置するようにして支持体１０の周方向に放射状に６個配設されている。
【００３７】
これらの剛性部材１２は、支持体１０の外径に応じて径方向へ移動しつつ軸方向へ移動可能な機構構造を有する。則ち、各々の剛性部材１２は、図１（ａ）の様に、支持体１０の小径部１０ｃから軸方向へ向けて上昇し、テーパー部１０ｂに差し掛かると互いに径方向へ広がりつつ外周面に沿って上昇する。そして、大径部１０ａに至ると、図１（ｂ）の様に、径方向への広がりを停止して外周面に沿って上昇する構造とされている。
【００３８】
また、押圧ローラ１３は支持体１０の中心軸と直交する中心軸を有した円柱形のローラで、支持体１０の周方向に放射状に３個配設されている。この押圧ローラ１３は、剛性部材１２から所定長さだけ上方に位置し、剛性部材１２との間に所定長さを保ちつつ剛性部材１２の移動に追随して移動する。また、剛性部材１２が支持体１０の下端に位置するときは、押圧ローラ１３は支持体１０の外周面から離れ、剛性部材１２が軸方向一端側へ向けて移動時には支持体１０の外周面を押圧するように付勢される構成とされている。
【００３９】
次に、この構成の製造装置１を用いた本発明の製造方法を、図３，図４を参照して説明する。
剛性部材１２を支持体１０の下端まで下げると、図３（ａ），図４（ａ）の様に、押圧ローラ１３は支持体１０の外周面から離れる。この状態でネットＮを開放端Ｎｂ側から軸方向全長に渡って支持体１０に被せると、開放端Ｎｂは支持体１０の小径部１０ｃに至り、巻き上げ部材１２の湾曲部下縁１２ｂに近接する。
【００４０】
剛性部材１２を支持体１０に対して所定速度で上昇させると、図４（ｂ）の様に、ネットＮの開放端Ｎｂは剛性部材１２の湾曲部下縁１２ｂから湾曲部１２ａに沿って径方向外方へ押し広げられるように案内される。一方、剛性部材１２の上昇に伴い、押圧ローラ１３が支持体１０の外周面へ向けて付勢され、ネットＮを支持体１０に押圧しつつ剛性部材１２に追随して上昇する。
【００４１】
剛性部材１２の湾曲部下縁１２ｂが支持体１０のテーパー部１０ｂに差し掛かるまで上昇すると、図４（ｃ）の様に、ネットＮの開放端Ｎｂ側は湾曲部１２ａに沿って巻き返され、巻き返された開放端ＮｂがネットＮの外周面に達する。このとき、巻き返されたネットＮの開放端Ｎｂは伸長した状態から縮もうとするため、開放端Ｎｂは下方へ僅かに反り返る。更に、ネットＮの外周部は支持体１０のテーパー部１０ｂに沿って傾斜しているので、ネットＮの開放端ＮｂはネットＮの外周面に巻き込むように近接する。
【００４２】
剛性部材１２の湾曲部下縁１２ｂがテーパー部１０ｂの中央に差し掛かるまで上昇すると、図４（ｄ），図３（ｂ）の様に、ネットＮの開放端ＮｂがネットＮの外周面に巻き込むように当接し、巻き返された部分が略円形となって巻回部Ｎｃが形成される。
【００４３】
以降は、図３（ｃ），（ｄ）の様に、形成された巻回部Ｎｃは巻き上げ部材１２の上昇に伴って湾曲部１２ａにより転動されてネットＮが軸方向全長に渡って巻き上げられる。そして、巻き上げが終了すると、図３（ｅ）の様に、押圧ローラ１３は径方向外方へ退動し、巻き上げられた充填材３を支持体１０から取り外す。
【００４４】
このように、本実施形態の製造装置１によれば、本発明の製造方法を効果的に実施可能であり、充填材３を短時間に効率良く製造することが可能となる。
このようにして巻き上げられた充填材３は、図６の様にほぼ球形であり、上部中央には閉塞端Ｎａが突出する。
また、充填材３は筒状のネットＮを巻き上げたものであり、外周部はネットＮの編み目が広がった状態で積層されている。これにより、充填材３に外力を加えると、編み目が収縮するだけでしわが生じることがなく自在に変形可能であり、上下方向および径方向に対して極めて高い弾力性を有する。
【００４５】
本実施形態で製された上部空間充填材３は、例えば、図７の様に、錠剤Ｔを収容した薬瓶３０の容器本体３１の上部に生じる空間３１ａに挿入される。充填材３は、閉塞端Ｎａを掴んで容器本体３１内に容易に挿入でき、栓３２を開いて充填材３の閉塞端Ｎａを掴んで容易に取り出すことができる。
特に、本実施形態の充填材３は、前記したように、極めて高い弾力性を有するので、内径の異なる容器や同一内径の容器でも上部空間容積が異なる場合にも優れた充填効果を発揮する。また、変形時にしわが生じないので、上部空間３１ａへ充填時に充填材３の内部に錠剤Ｔが入り込むことがなく、充填材３の取り出し時に錠剤Ｔが付着してが飛び出すような不具合が生じない。
【００４６】
尚、上記製造装置１では、固定された支持体１０の外周面に沿って軸方向に剛性部材（巻き上げ部材）１２および押圧ローラ１３が移動する構成として述べたが、本発明はこのような構成に限られるものではない。
例えば、支持体１０を軸方向に移動させ、押圧ローラ１３を支持体１０の外周面に押圧しつつ、支持体１０の外径寸法に合わせて剛性部材１２を径方向へ移動させる構成を採ることも可能である。
【００４７】
また、上記製造装置１では剛性部材１２として、図２に示した方形材の一部を円弧状に切り欠いたものを用いた。しかし、例えば、図５の様に、上面視略扇形を有する部材の上部内周側を切り欠いて湾曲部１５ａを形成した剛性部材１５を用いても良い。この剛性部材１５は、内周面１５ｄを支持体１０の小径部１０ｃの曲率に略一致させ、湾曲部１５ａをネットＮで形成される巻回部Ｎｃの外周部に沿うように形成することにより、巻回部Ｎｃの形成を一層促進させることが可能となる。
【００４８】
また、上記製造装置１では、支持体１０の周囲に６個の剛性部材１２と３個の押圧ローラ１３を配設した構成としたが、ネットＮの材質や巻き上げ径に応じて適宜の数の剛性部材１２および押圧ローラを配設することができる。
【００４９】
更に、上記製造装置１では、支持体１０の表面にウレタンゴムを展張してネットＮの滑り止めを行う構成とした。しかし、このような構成に限らず、例えば、支持体１０の外周面に軸方向に沿って長尺のゴムベルトを展張しても同様の効果を奏することが可能である。この場合には、複数のゴムベルト（例えば４本）を周方向に等間隔で配置するのが好ましい。このゴムベルトは支持体１０の全長にわたって設けてもよいが、少なくとも大径部１０ａの全長にわたって設けられていればよく、テーパー部１０ｂや小径部１０ｃにおいては滑り止めを行う必要はない。また、金属製の支持体１０の表面全体に滑り止め剤を塗布や蒸着等等により表面被覆してもよい。
【００５０】
（第２実施形態）
次に、本発明の第２実施形態に係る製造装置２を図を参照して説明する。
尚、製造装置２に採用する支持体は、前記第１実施形態で示したものと同一である。従って、同一部分には同一の符号を付して重複した説明を省略する。
図８は本実施形態の製造装置２を示す斜視図、図９は製造装置２を用いて本発明の製造方法を実施するときの製造工程を示す説明図、図１０は図９に示す製造工程における巻回部の形成過程を詳細に示す拡大図である。
【００５１】
本実施形態の製造装置２は、図８の様に、支持体１０と巻き上げ手段２０を備えて構成される。
支持体１０は、前記した製造装置１に用いたものと同一である。また、巻き上げ手段２０は巻き上げ部材（紐状部材）２１と押圧パッド（押圧部）１３で構成される。
【００５２】
紐状部材２１は柔軟性を有した紐であり、一端が支持体１０の上端部１０ｄに固定され、他端は支持体１０の軸方向に沿って下方（軸方向他端側）に伸び、途中で折り返されて再度上方（軸方向一端側）に伸びている。この紐状部材２１は、支持体１０の周方向に放射状に６本配設されている。
これらの紐状部材２１は、他端側を一斉に軸方向に移動可能な機構を備えており、各紐状部材２１の折り返し部位で形成される湾曲部２１ａが支持体１０の外周面に沿って軸方向へ同時に移動可能である。
【００５３】
押圧パッド２２は方形平板材で成り、支持体１０の外周に沿う各紐状部材２１の径方向外方に放射状に６個配設されている。この押圧パッド２２は、紐状部材２１の湾曲部２１ａの上方に位置し、湾曲部２１ａの軸方向への移動に伴って追随して移動する。
則ち、予め、湾曲部２１ａと押圧パッド２２との最小距離ａおよび最大距離ｂを定めておき、湾曲部２１ａの移動に伴い押圧パッド２２との距離が最小距離ａとなれば、一旦、湾曲部２１ａの移動を停止し、湾曲部２１ａとの距離が最大距離ｂとなるように押圧パッド２２を軸方向へ移動させる。この後に、湾曲部２１ａの移動を再開する動作を繰り返す。
また、紐状部材２１の湾曲部２１ａが支持体１０の下端に位置するときは、押圧パッド２２は支持体１０の外周面から離れ、湾曲部２１ａが軸方向一端側へ移動時には支持体１０の外周面を押圧するように付勢される構成とされている。
【００５４】
次に、製造装置２を用いた本発明の製造方法を、図９，図１０を参照して説明する。
紐状部材２１の他端側を軸方向へ移動させて湾曲部２１ａを支持体１０の下端まで下降させると、図９（ａ），図１０（ａ）の様に、押圧パッド２２は支持体１０の外周面から離れる。この状態で、ネットＮを開放端Ｎｂ側から軸方向全長に渡って支持体１０に被せると、開放端Ｎｂは支持体１０の小径部１０ｃに位置し、紐状部材２１の湾曲部２１ａと近接する。
【００５５】
紐状部材２１の他端側を所定速度で軸方向一端側へ向けて上昇させると、図１０（ｂ）の様に、ネットＮの開放端Ｎｂは紐状部材２１の湾曲部１２ａに沿って径方向外方へ向けて押し広げられるように案内される。一方、押圧パッド２２は支持体１０の外周面へ向けて付勢され、ネットＮを紐状部材２１と共に支持体１０に押圧する。
【００５６】
湾曲部２１ａがテーパー部１０ｂに近づくと、図１０（ｃ）の様に、ネットＮの開放端Ｎｂ側は湾曲部２１ａに沿って巻き返され、巻き返された開放端ＮｂがネットＮの外周面に近接する。このとき、巻き返されたネットＮの開放端Ｎｂは伸長した状態から縮もうとするため、開放端Ｎｂは僅かに下方へ反り返る。更に、ネットＮの外周部は支持体１０のテーパー部１０ｂに沿って傾斜しているので、ネットＮの開放端ＮｂはネットＮの外周部に巻き込むように近接する。
【００５７】
湾曲部２１ａが上昇してテーパー部１０ｂに差し掛かると、図９（ｂ），図１０（ｄ）の様に、ネットＮの開放端ＮｂがネットＮの外周部に巻き込むように当接し、巻き返された部分が略円形となって巻回部Ｎｃが形成される。
【００５８】
以降は、図９（ｃ），（ｄ）の様に、湾曲部２１ａの上昇に伴って、巻回部Ｎｃが湾曲部２１ａによって転動してネットＮが巻き上げられる。巻き上げが終了すると、図９（ｅ）の様に、押圧パッド２２は径方向外方へ退動し、巻き上げられた充填材３を支持体１０から取り外す。
【００５９】
このように、本実施形態の製造装置２によれば、本発明の製造方法を効果的に実施することができ、充填材３を短時間に効率良く製造することが可能となる。製造装置２で巻き上げられた充填材３は、前記図６に示したものと同一の形状を有し、優れた充填効果を発揮する。
【００６０】
尚、本実施形態の製造装置２では、固定した支持体１０に対して紐状部材２１および押圧パッド２２を移動させる構成として述べたが、本発明はこのような構成に限られるものではない。例えば、紐状部材２１の他端側を固定し、支持体１０を軸方向下方へ移動させ、支持体１０の移動に合わせて押圧パッド２２を移動させつつ押圧しながら巻き上げる構成を採ることも可能である。
【００６１】
また、本実施形態の製造装置２では、紐状部材２１の折り返し部位で形成される湾曲部２１ａによってネットＮの開放端Ｎｂを巻き返すため、紐状部材２１やネットＮの材質によっては、巻回部Ｎｃが形成され難く、その半径を規制することも困難な場合がある。
この場合は、紐状部材２１の形成する湾曲部２１ａの形状を調整するために、例えば、湾曲部２１ａの上方近傍に、紐状部材２１の移動方向を偏向させるガイド部材を配設し、このガイド部材と湾曲部２１ａとの距離を保ちつつ移動する構成を採ることができる。
この構成によれば、湾曲部２１ａ近傍では紐状部材２１の移動方向がガイド部材２３によって支持体１０の外周面へ向かう方向に偏向される。これにより、半径を規制した巻回部Ｎｃを安定して形成させることが可能である。
【００６２】
また、上記製造装置２では、支持体１０の周囲に６本の紐状部材２１と６個の押圧パッド２２を配設した構成としたが、ネットＮの材質や巻き上げ径に応じて適宜の数の紐状部材２１および押圧パッド２２を配設することができる。
また、上記製造装置２において、押圧パッド２２に代えて、前記第１実施形態の製造装置１に採用した押圧ローラ１３を設けることも可能である。
また、前記第１実施形態で述べた製造装置１において、押圧ローラ１３に代えて、製造装置２で述べた押圧パッド２２を採用することも可能である。
【００６３】
【発明の効果】
本発明によれば、サイズの異なる容器であっても上部空間を効果的に充填でき、しかも、挿入や取り出しが容易で収容物が付着しない優れた充填材を効率良く低コストで製造することが可能となる。
【図面の簡単な説明】
【図１】（ａ），（ｂ）は、本発明の実施形態に係る上部空間充填材の製造装置を示す斜視図である。
【図２】図１の製造装置に採用する巻き上げ部材を示す斜視図である。
【図３】（ａ）〜（ｆ）は、図１に示す製造装置を用いて本発明の製造方法を実施する製造工程を示す説明図である。
【図４】（ａ）〜（ｄ）は、図３に示した製造工程における巻回部の形成過程を示す拡大図である。
【図５】図１に示す製造装置に採用可能な別の巻き上げ部材を示す斜視図である。
【図６】図１に示す製造装置によって製造された上部空間充填材を示す斜視図である。
【図７】図６に示す上部空間充填材を容器に挿入した状態を示す断面図である。
【図８】本発明の別の実施形態に係る上部空間充填材の製造装置を示す斜視図である。
【図９】（ａ）〜（ｆ）は、図８に示す製造装置を用いて本発明の製造方法を実施する製造工程を示す説明図である。
【図１０】（ａ）〜（ｄ）は、図９に示した製造工程における巻回部の形成過程を示す拡大図である。
【符号の説明】
Ｎ筒状のネット
Ｎａネットの一端（ネットの閉塞端部）
Ｎｂネットの他端部（ネットの開放端部）
Ｎｃ巻回部
１，２上部空間充填材の製造装置
１０支持体
１０ａ支持体の大径部
１０ｂ支持体のテーパー部
１０ｃ支持体の小径部
１１巻き上げ手段
１２巻き上げ部材（剛性部材）
１２ａ湾曲部
１３押圧部（押圧ローラ）
２１巻き上げ部材（紐状部材）
２１ａ湾曲部
２２押圧部（押圧パッド）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for producing an upper space filler for filling a space generated in an upper part of a container containing a solid substance such as a tablet.
[0002]
[Prior art]
Solids such as tablets and capsules are often sold in glass bottles or synthetic resin containers and sold, and in order to prevent the contents from moving or breaking in the container during transportation, A filler is inserted into the upper space of the container.
[0003]
Conventionally, as such a filler, a material obtained by appropriately rounding a synthetic resin film or the like, or a material obtained by molding a synthetic resin material in accordance with the container size is used.
Such a filler is additionally provided in order to prevent movement of the contents during transportation, and a material price including a processing cost is required to be extremely low.
[0004]
[Problems to be solved by the invention]
However, the filling material using a resin film or the like is low in material price, but is difficult to take out when opening the plug. In addition, there is a problem that the tablet enters the rolled film and the tablet pops out when the film is taken out. .
In addition, the dedicated filling material made of a resin molded product is expensive and cannot be shared by containers of different container sizes, and even if the container size is the same, a sufficient filling effect cannot be obtained if the upper space volume is different. There was a thing.
[0005]
This invention is proposed in view of the said situation, and provides the novel manufacturing method and manufacturing apparatus for manufacturing the top space filler which can fill top space effectively also in the container from which size differs. With the goal.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the present inventors have taken the following technical means.
That is, the manufacturing method of the upper space filler of the present invention includes a step of covering a columnar support over the entire length in the axial direction with a stretchable cylindrical net having one axial end closed and the other open. A step of forming a winding portion at the open end of the net by spreading the other end of the net outwardly in the radial direction of the support and winding it back to the one end in the axial direction; A cylindrical net is wound over the entire length in the axial direction, and the net is configured in a substantially lump or spherical shape.
[0007]
Here, the cylindrical net employed in the present invention is preferably, for example, a cylindrical net having elasticity and flexibility made by molding a synthetic resin material. Therefore, in the following description, a configuration using a cylindrical net made of such a synthetic resin will be described.
[0008]
Since the synthetic resin net has stretchability and flexibility, the shape is unstable as it is and it is difficult to wind up, but according to the present invention, the stretchability and flexibility By covering a cylindrical net having a diameter on a support having an outer diameter larger than the inner diameter in a steady state of the net, it is supported in a stable state to ensure workability.
[0009]
Further, the winding part is formed by winding the other end of the net toward the outer side in the radial direction of the support while winding it back to one end in the axial direction. When the winding portion is formed, the other end portion of the wound net comes into contact with the outer peripheral portion of the net so that the shape is stabilized. Then, the net can be easily wound by rolling the winding portion having a stable shape toward one end in the axial direction.
[0010]
Further, the upper space filler manufacturing apparatus of the present invention includes a columnar support on which a cylindrical net having elasticity that is closed at one end in the axial direction and opened at the other end is covered over the entire length in the axial direction, Hoisting means for hoisting the net substantially in a lump or sphere, and the hoisting means pushes the other end of the net outward in the radial direction of the support and rolls it back to one end in the axial direction to open the net. In addition, a cylindrical net is wound up over the entire length in the axial direction so as to form a lump or a sphere by rolling the winding portion toward one end side in the axial direction. ing.
[0011]
Such a manufacturing apparatus can be suitably used in the above-described manufacturing method of the present invention. By providing the support and the winding means, the net can be supported in a stable state and efficiently wound in a short time. is there.
[0012]
Here, the net used in the present invention is preferably made by molding a flexible synthetic resin material such as vinyl chloride resin or polyolefin resin material. Among polyolefin resins, polyethylene resin and polypropylene resin are optimal because of their high chemical resistance. When using a net made of a synthetic resin, a net formed in a cylindrical shape and closed at one end in the axial direction is used.
[0013]
In the manufacturing apparatus of the present invention, the winding means can include a winding member having a curved portion that is disposed on the outer peripheral portion of the support and guides the open end of the net. The curved portion of the winding member can be moved relative to the support in the axial direction. Further, the other end of the net is bent so that a winding portion is formed by relatively moving the bent portion at a position in contact with the other end of the net placed on the support to the one end side in the axial direction. Can be configured to be guided by. Further, the winding portion is guided by the bending portion so that the winding portion rolls toward the one end side in the axial direction by relatively moving the bending portion from the other end side to the one end side of the net. It can be.
[0014]
It is possible to adopt either a configuration in which the winding member is moved in the axial direction with respect to the fixed support member or a configuration in which the support member is moved in the axial direction with respect to the fixed winding member.
[0015]
According to such a configuration, the other end portion of the net is guided by the curved portion of the winding member to form the wound portion, and the formed wound portion is rolled toward the one end side of the net by the curved portion. It is possible to guide and efficiently wind up in a short time.
[0016]
In the manufacturing apparatus of the present invention, the winding member is a rigid member disposed on the outer peripheral portion of the support, and the side surface on one end side in the axial direction of the rigid member is a concave surface that functions as a curved portion. The bending portion can be configured to move in the axial direction by moving the rigid member in the axial direction with respect to the support.
[0017]
According to this, when the rigid member forming the winding member is relatively moved toward the one end side of the net with respect to the support, the other end of the net is outside the radial direction of the support along the curved portion of the rigid member. It is rewound toward the one end side in the axial direction while being spread toward the end. Thereby, a winding part is formed in the other end part of a net. When the rigid member is further moved, the formed winding portion rolls toward the one end side in the axial direction by the bending portion, and the net can be wound into a lump or a sphere over the entire axial length. .
[0018]
Here, in the manufacturing apparatus of the present invention, the inventors conducted a manufacturing test by changing the curvature radius of the curved portion of the rigid member and the moving speed of the rigid member in various ways, and found that the curvature radius of the curved portion was 50 mm. When it exceeded, it turned out that the external dimensions of the wound-up filler vary greatly. In addition, when the curvature radius of the curved portion is less than 10 mm, the other end portion of the net cannot be sufficiently wound back, and it is difficult to form the winding portion.
Therefore, the outer dimension of the wound up filler can be adjusted by setting the curvature radius of the curved portion within the range of 10 mm to 50 mm.
[0019]
Further, as a result of the test, it has been found that the height of the wound up filler increases as the moving speed of the rigid member increases, and conversely, when the moving speed is decreased, the height of the wound up filler decreases. Moreover, even if the moving speed of the rigid member was changed in the range of 50 mm / min to 1250 mm / min, the winding could be performed.
Therefore, by adjusting the radius of curvature of the curved portion of the rigid member and the moving speed of the rigid member, it is possible to manufacture a filler having a desired outer diameter and height.
[0020]
The winding member may be a flexible string member. One end of the string-like member may be fixed to one end of the support. It is preferable that the string-like member extends to the other end side along the axial direction between the support and the net covered by the support. Furthermore, the string-like member can be folded back at the open end of the net, and the other end of the string-like member can be extended to one end in the axial direction. And it can be set as the structure which a curved part moves to an axial direction one end side by pulling up the other end part of a string-like member to an axial direction one end side.
[0021]
Note that either the configuration in which the other end of the string-like member is moved in the axial direction with respect to the fixed support, or the configuration in which the support is moved in the axial direction with respect to the string-like member with the other end fixed. A configuration can also be employed.
[0022]
According to such a configuration, the other end portion of the net is guided by the curved portion formed by the folded portion of the string-like member to form the wound portion, and the formed wound portion is connected to the one end in the axial direction of the net by the curved portion. It is possible to efficiently roll up by rolling to the side.
[0023]
The inventors of the present invention also performed a manufacturing test by changing the curvature radius of the curved portion of the string-like member and the pulling-up speed of the string-like member in various ways. As a result of the test, it is found that when the net is rolled up with the curvature radius of the curved portion being approximately 10 mm, the wound portion can be stably formed at the other end of the net, and the outer dimensions after winding are not varied. It was.
[0024]
Also, as a result of the test, the height of the wound up filler increases with an increase in the pulling speed of the string-like member, and conversely, when the lifting speed is lowered, the height of the wound up filler is reduced. It was. Further, even when the moving speed of the bending portion was changed in the range of 50 mm / min to 1250 mm / min, the winding was possible.
Accordingly, the curvature radius of the curved portion formed by the string-like member is set to about 10 mm, and the filling having the desired outer diameter and height is achieved by adjusting the moving speed of the curved portion accompanying the pulling-up of the string-like member. The material can be manufactured.
[0025]
Furthermore, the plurality of winding members can be arranged in the circumferential direction of the support. As described above, a net made of a synthetic resin has flexibility and stretchability. For this reason, when the number of winding members is small, it is difficult for the other end side of the net to be rewound in the circumferential portion where the winding member is not arranged, and a uniform winding portion is provided over the entire circumference of the net. It is difficult to form. However, according to the present invention, since the plurality of winding members are arranged in the circumferential direction of the support body, the interval between the winding members can be reduced, and the other end side of the net can be uniformly distributed over the entire circumferential direction. The winding portion can be stably formed by rewinding.
[0026]
The winding means may include a pressing portion that presses and fixes the net to the support from the outer peripheral side, and the pressing portion may move in the axial direction in accordance with the axial movement of the bending portion. . According to this, even when a force toward the one end side in the axial direction is applied to the net by the movement of the winding member by pressing the outer peripheral portion of the net toward the support by the pressing portion, the net is against the support. A stable winding process is possible without shifting.
[0027]
The position where the pressing portion is provided is preferably one end side in the axial direction of the bending portion and in the vicinity of the bending portion. If the pressing portion is too far from the curved portion, the flexibility of the net tends to cause bending at the time of winding, and stable winding becomes difficult. In addition, the pressing portion can take various forms such as a configuration in which a pressing pad movable in the radial direction of the support is provided, and a configuration in which a pressing roller is provided. When the pressing pad is provided, it is possible to adopt a configuration in which the position of the pressing pad is sequentially shifted toward the one end side in the axial direction every time the bending portion moves by a predetermined length. Further, when the pressing roller is provided, a configuration is adopted in which the pressing roller also follows the one end in the axial direction so as to keep the distance between the bending portion and the pressing roller constant as the bending portion moves. Can do.
[0028]
By the way, in order to suppress the deviation of the net, the support may be formed of a material having a large frictional force generated between the net made of synthetic resin. Examples of the material having a large frictional force against the synthetic resin include silicone rubber and urethane rubber. Further, these rubbers are preferably those having a hardness in the range of HRC20 to HRC90 indicated by the Rockwell hardness test, and the hardness range of HRC50 to HRC60 is optimal. By spreading a rubber material having such hardness on the support (surface), the frictional force generated between the rubber and the synthetic resin net increases, and the net of the net with respect to the support is surely coupled with the pressing by the pressing portion. To be prevented. This makes it possible to perform a stable winding process.
[0029]
The support has a large-diameter portion on one end side in the axial direction, a small-diameter portion on the other end side in the axial direction, and a tapered portion positioned between the large-diameter portion and the small-diameter portion. The other end of the formed net can be positioned on the outer periphery of the small diameter portion. According to this, the net located in the tapered portion is inclined so as to spread toward the one end side in the axial direction along the outer peripheral surface of the tapered portion. Therefore, the other end portion of the net that has been wound back by the winding member abuts so as to be wound around the outer peripheral portion of the net as compared with the case where the taper portion is not provided. Thereby, compared with the case where a taper part is not provided, a winding part is formed stably and it becomes possible to perform efficient winding.
[0030]
The present inventors performed a production test by changing the outer diameter and length of each part of the support in the production apparatus of the present invention in various ways. As a result, the outer diameter of the support capable of winding up the net differs depending on the material of the net, the wire diameter, or the diameter of the winding part, but in particular, the influence of the diameter of the winding part was large. As a result of the test, when the outer diameter of the support is 2/5 to 4/5 of the diameter of the winding part, the outer diameter of the support is approximately 1/3 of the diameter of the winding part. It was confirmed that the most stable winding was performed.
[0031]
In addition, as a condition for performing stable winding, it is preferable to set the outer diameter of the outer diameter of the large diameter portion to 3/5 or less in the range from the other end of the net to 100 mm with the net covered on the support. It has also been found that the length of the tapered portion should be set to 80 mm or more.
[0032]
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiments of the present invention will be described below with reference to the drawings.
(First embodiment)
FIG. 1 is a perspective view showing a manufacturing apparatus 1 according to the first embodiment of the present invention, FIG. 2 is an enlarged perspective view showing a winding member employed in the manufacturing apparatus 1, and FIG. 3 shows the manufacturing apparatus 1 according to the manufacturing method of the present invention. FIG. 4 is an enlarged view showing in detail the process of forming the winding part in the manufacturing process of FIG. 3, and FIG. 5 is a perspective view showing a modification of the winding member. 6 is a perspective view showing an upper space filler manufactured by the manufacturing apparatus 1, and FIG. 7 is a cross-sectional view showing a state where the upper space filler of FIG. 6 is mounted on a medicine container.
[0033]
Here, the net N processed using the manufacturing apparatus 1 of the present embodiment is formed by processing a polyethylene resin material into a cylindrical net material, and has stretchability and flexibility. At one end in the axial direction of the net N, as shown in FIG. 3A, closed end Na is formed by heat welding, and the other end in the axial direction is opened to form an open end Nb. Further, the inner diameter of the net N in a steady state is smaller than the outer diameter of the support described later.
[0034]
On the other hand, the manufacturing apparatus 1 of this embodiment includes a columnar support 10 and a winding means 11 as shown in FIG.
[0035]
The support 10 has an upper large-diameter portion 10a, a lower small-diameter portion 10c, and a tapered portion 10b positioned therebetween, and an upper end portion 10d is hemispherical.
In this embodiment, the length of the tapered portion 10b of the support 10 is 80 mm, and the outer diameter of the small diameter portion 10c is approximately 2/5 with respect to the large diameter portion 10a. When the support body 10 is covered with the net N over the entire length in the axial direction, the open end Nb of the net N is positioned on the outer peripheral portion of the small diameter portion 10c as shown in FIG. The taper portion 10b and the outer diameter of the support 10 at a site of 100 mm from the open end Nb of the net toward one end side in the axial direction (closed end Na side) are approximately 3/5 of the large diameter portion 10a. The outer diameter and length of the small diameter portion 10c are adjusted.
Further, urethane rubber (not shown) with Rockwell hardness HRC20 is stretched on the surface of the support 10 to prevent the net N from slipping.
[0036]
The winding means 11 includes a winding member (rigid member) 12 and a pressing roller (pressing portion) 13.
As shown in FIG. 2, the rigid member 12 is a member obtained by notching a part of a rectangular material having a predetermined thickness in an arc shape, and the concave surface of the notched portion functions as a curved portion 12a. Further, the curved portion lower edge 12b and the curved portion upper edge 12c positioned at the end of the curved portion 12a are pointed like a wedge, and the inner side surface 12d adjacent to the curved portion lower edge 12b is a flat surface.
The rigid member 12 is formed so that the inner surface 12 d is close to the outer peripheral surface of the support 10, that is, the curved portion 12 a is positioned on the inner surface 12 on one end side in the axial direction of the rigid member 12. Six pieces are arranged radially in the circumferential direction.
[0037]
These rigid members 12 have a mechanism structure that can move in the axial direction while moving in the radial direction according to the outer diameter of the support 10. That is, as shown in FIG. 1A, each rigid member 12 rises in the axial direction from the small diameter portion 10c of the support 10 and spreads in the radial direction when reaching the tapered portion 10b. Ascend along. And when it reaches the large diameter part 10a, it is set as the structure which stops the spread to radial direction and raises along an outer peripheral surface like FIG.1 (b).
[0038]
The pressing rollers 13 are cylindrical rollers having a central axis orthogonal to the central axis of the support 10, and three pressing rollers 13 are arranged radially in the circumferential direction of the support 10. The pressing roller 13 is positioned above the rigid member 12 by a predetermined length, and moves following the movement of the rigid member 12 while maintaining the predetermined length with the rigid member 12. When the rigid member 12 is positioned at the lower end of the support 10, the pressing roller 13 is separated from the outer peripheral surface of the support 10, and when the rigid member 12 moves toward one end in the axial direction, the outer peripheral surface of the support 10 is moved. It is set as the structure urged | biased so that it may press.
[0039]
Next, the manufacturing method of this invention using the manufacturing apparatus 1 of this structure is demonstrated with reference to FIG. 3, FIG.
When the rigid member 12 is lowered to the lower end of the support 10, the pressing roller 13 is separated from the outer peripheral surface of the support 10 as shown in FIGS. 3 (a) and 4 (a). In this state, when the net N is put on the support body 10 from the open end Nb side over the entire length in the axial direction, the open end Nb reaches the small diameter portion 10c of the support body 10 and is close to the lower edge 12b of the curved portion of the winding member 12.
[0040]
When the rigid member 12 is raised with respect to the support 10 at a predetermined speed, the open end Nb of the net N is radially extended from the curved portion lower edge 12b of the rigid member 12 along the curved portion 12a as shown in FIG. Guided to be spread outward. On the other hand, as the rigid member 12 rises, the pressing roller 13 is urged toward the outer peripheral surface of the support 10, and rises following the rigid member 12 while pressing the net N against the support 10.
[0041]
When the curved portion lower edge 12b of the rigid member 12 rises until reaching the tapered portion 10b of the support 10, the open end Nb side of the net N is wound back along the curved portion 12a as shown in FIG. The opened open end Nb reaches the outer peripheral surface of the net N. At this time, since the open end Nb of the wound net N tries to shrink from the extended state, the open end Nb slightly warps downward. Furthermore, since the outer peripheral portion of the net N is inclined along the tapered portion 10 b of the support 10, the open end Nb of the net N is close to be wound around the outer peripheral surface of the net N.
[0042]
When the curved portion lower edge 12b of the rigid member 12 rises to reach the center of the tapered portion 10b, the open end Nb of the net N is wound around the outer peripheral surface of the net N as shown in FIGS. 4 (d) and 3 (b). Thus, the wound portion Nc is formed by forming a substantially circular portion in contact with each other.
[0043]
Thereafter, as shown in FIGS. 3C and 3D, the formed winding portion Nc is rolled by the bending portion 12a as the winding member 12 is lifted, and the net N is wound up over the entire length in the axial direction. It is done. When the winding is completed, the pressing roller 13 is retracted radially outward as shown in FIG. 3E, and the wound up filler 3 is removed from the support 10.
[0044]
Thus, according to the manufacturing apparatus 1 of the present embodiment, the manufacturing method of the present invention can be effectively implemented, and the filler 3 can be efficiently manufactured in a short time.
The filler 3 wound up in this way is substantially spherical as shown in FIG. 6, and the closed end Na protrudes from the upper center.
Further, the filler 3 is obtained by winding up a cylindrical net N, and the outer peripheral portion is laminated with the stitches of the net N spread. As a result, when an external force is applied to the filler 3, it can be freely deformed without causing wrinkles only by contraction of the stitches, and has extremely high elasticity in the vertical direction and the radial direction.
[0045]
The upper space filling material 3 manufactured in the present embodiment is inserted into a space 31a generated in the upper part of the container body 31 of the medicine bottle 30 containing the tablets T as shown in FIG. The filler 3 can be easily inserted into the container body 31 by grasping the closed end Na, and can be easily taken out by opening the stopper 32 and grasping the closed end Na of the filler 3.
In particular, as described above, the filler 3 according to the present embodiment has extremely high elasticity, and therefore exhibits an excellent filling effect even when containers having different inner diameters or containers having the same inner diameter have different upper space volumes. Moreover, since wrinkles do not occur during deformation, the tablet T does not enter the filling material 3 when filling the upper space 31a, and there is no problem that the tablet T adheres and pops out when the filling material 3 is taken out. .
[0046]
In the manufacturing apparatus 1 described above, the rigid member (winding member) 12 and the pressing roller 13 are moved in the axial direction along the outer peripheral surface of the fixed support 10. However, the present invention has such a configuration. It is not limited to.
For example, a configuration is adopted in which the rigid member 12 is moved in the radial direction in accordance with the outer diameter of the support 10 while the support 10 is moved in the axial direction and the pressing roller 13 is pressed against the outer peripheral surface of the support 10. Is also possible.
[0047]
Further, in the manufacturing apparatus 1, the rigid member 12 in which a part of the rectangular material shown in FIG. 2 is cut out in an arc shape is used. However, for example, as shown in FIG. 5, a rigid member 15 in which a curved portion 15 a is formed by notching the upper inner peripheral side of a member having a substantially fan shape when viewed from above may be used. The rigid member 15 is formed by making the inner peripheral surface 15d substantially coincide with the curvature of the small-diameter portion 10c of the support 10 and forming the curved portion 15a along the outer peripheral portion of the winding portion Nc formed by the net N. The formation of the winding part Nc can be further promoted.
[0048]
In the manufacturing apparatus 1, the six rigid members 12 and the three pressing rollers 13 are disposed around the support body 10. However, an appropriate number of the members can be selected depending on the material of the net N and the winding diameter. A rigid member 12 and a pressure roller can be provided.
[0049]
Further, the manufacturing apparatus 1 is configured to prevent the net N from slipping by spreading urethane rubber on the surface of the support 10. However, the present invention is not limited to such a configuration, and for example, a similar effect can be achieved by extending a long rubber belt along the axial direction on the outer peripheral surface of the support 10. In this case, it is preferable to arrange a plurality of rubber belts (for example, four) at equal intervals in the circumferential direction. The rubber belt may be provided over the entire length of the support body 10, but it is sufficient that the rubber belt is provided at least over the entire length of the large-diameter portion 10a, and the taper portion 10b and the small-diameter portion 10c do not need to be slipped. Further, the entire surface of the metal support 10 may be coated with a non-slip agent by coating or vapor deposition.
[0050]
(Second Embodiment)
Next, the manufacturing apparatus 2 which concerns on 2nd Embodiment of this invention is demonstrated with reference to figures.
In addition, the support body employ | adopted as the manufacturing apparatus 2 is the same as what was shown in the said 1st Embodiment. Accordingly, the same portions are denoted by the same reference numerals, and redundant description is omitted.
FIG. 8 is a perspective view showing the manufacturing apparatus 2 of this embodiment, FIG. 9 is an explanatory view showing a manufacturing process when the manufacturing method of the present invention is carried out using the manufacturing apparatus 2, and FIG. 10 is a manufacturing process shown in FIG. It is an enlarged view which shows the formation process of the winding part in detail.
[0051]
As shown in FIG. 8, the manufacturing apparatus 2 of the present embodiment includes a support 10 and a winding means 20.
The support 10 is the same as that used in the manufacturing apparatus 1 described above. The winding means 20 includes a winding member (string member) 21 and a pressing pad (pressing portion) 13.
[0052]
The string-like member 21 is a string having flexibility, one end is fixed to the upper end portion 10d of the support 10 and the other end extends downward (the other end in the axial direction) along the axial direction of the support 10, It is folded halfway and extends upward (on the one end side in the axial direction) again. Six string members 21 are arranged radially in the circumferential direction of the support 10.
These string-like members 21 are provided with a mechanism capable of moving the other end side in the axial direction all at once, and a curved portion 21 a formed at a folded portion of each string-like member 21 extends along the outer peripheral surface of the support 10. Can be moved simultaneously in the axial direction.
[0053]
The pressing pads 22 are made of a rectangular flat plate material, and six radial pads are arranged radially outward of the string-like members 21 along the outer periphery of the support 10. The pressing pad 22 is located above the bending portion 21a of the string-like member 21, and moves following the movement of the bending portion 21a in the axial direction.
That is, the minimum distance a and the maximum distance b between the bending portion 21a and the pressing pad 22 are determined in advance, and once the distance from the pressing pad 22 becomes the minimum distance a as the bending portion 21a moves, the bending is temporarily performed. The movement of the part 21a is stopped, and the pressing pad 22 is moved in the axial direction so that the distance from the bending part 21a becomes the maximum distance b. Thereafter, the operation of resuming the movement of the bending portion 21a is repeated.
Further, when the curved portion 21a of the string-like member 21 is positioned at the lower end of the support body 10, the pressing pad 22 is separated from the outer peripheral surface of the support body 10, and when the curved portion 21a moves to one end side in the axial direction, It is set as the structure urged | biased so that an outer peripheral surface may be pressed.
[0054]
Next, the manufacturing method of this invention using the manufacturing apparatus 2 is demonstrated with reference to FIG. 9, FIG.
When the other end side of the string-like member 21 is moved in the axial direction and the bending portion 21a is lowered to the lower end of the support body 10, the pressing pad 22 is supported by the support body as shown in FIGS. 9 (a) and 10 (a). 10 away from the outer peripheral surface. In this state, when the net N is put on the support body 10 from the open end Nb side over the entire length in the axial direction, the open end Nb is positioned at the small diameter portion 10c of the support body 10 and close to the curved portion 21a of the string-like member 21 To do.
[0055]
When the other end side of the string-like member 21 is raised toward the one end side in the axial direction at a predetermined speed, the open end Nb of the net N extends along the curved portion 12a of the string-like member 21 as shown in FIG. It is guided so as to be pushed outward in the radial direction. On the other hand, the pressing pad 22 is urged toward the outer peripheral surface of the support 10 and presses the net N together with the string-like member 21 against the support 10.
[0056]
When the curved portion 21a approaches the tapered portion 10b, the open end Nb side of the net N is rewound along the curved portion 21a as shown in FIG. Close to the surface. At this time, since the open end Nb of the wound net N tries to shrink from the extended state, the open end Nb slightly warps downward. Furthermore, since the outer peripheral portion of the net N is inclined along the tapered portion 10b of the support body 10, the open end Nb of the net N is close to be wound around the outer peripheral portion of the net N.
[0057]
When the curved portion 21a rises and reaches the tapered portion 10b, the open end Nb of the net N comes into contact with the outer peripheral portion of the net N as shown in FIGS. The returned portion is substantially circular, and the winding portion Nc is formed.
[0058]
Thereafter, as shown in FIGS. 9C and 9D, as the bending portion 21a rises, the winding portion Nc rolls by the bending portion 21a and the net N is wound up. When the winding is completed, as shown in FIG. 9E, the pressing pad 22 is retracted radially outward, and the wound up filler 3 is removed from the support 10.
[0059]
Thus, according to the manufacturing apparatus 2 of this embodiment, the manufacturing method of this invention can be implemented effectively and it becomes possible to manufacture the filler 3 efficiently in a short time. The filler 3 wound up by the manufacturing apparatus 2 has the same shape as that shown in FIG. 6 and exhibits an excellent filling effect.
[0060]
In addition, in the manufacturing apparatus 2 of this embodiment, although described as a structure which moves the string-like member 21 and the press pad 22 with respect to the fixed support body 10, this invention is not limited to such a structure. For example, it is also possible to adopt a configuration in which the other end side of the string-like member 21 is fixed, the support 10 is moved downward in the axial direction, and the press pad 22 is moved while being pressed in accordance with the movement of the support 10 and rolled up. It is.
[0061]
Further, in the manufacturing apparatus 2 of the present embodiment, the open end Nb of the net N is rewound by the curved portion 21a formed at the folded portion of the cord-like member 21, so that depending on the material of the cord-like member 21 and the net N, the winding The portion Nc is difficult to be formed and it is sometimes difficult to regulate the radius.
In this case, in order to adjust the shape of the bending portion 21a formed by the string-like member 21, for example, a guide member for deflecting the moving direction of the string-like member 21 is disposed near the upper portion of the bending portion 21a. It is possible to adopt a configuration that moves while maintaining the distance between the guide member and the bending portion 21a.
According to this configuration, the moving direction of the string-like member 21 is deflected by the guide member 23 in the direction toward the outer peripheral surface of the support body 10 in the vicinity of the bending portion 21a. Thereby, it is possible to form stably the winding part Nc which controlled the radius.
[0062]
Further, in the manufacturing apparatus 2 described above, the six string-like members 21 and the six pressing pads 22 are disposed around the support body 10, but an appropriate number is set according to the material of the net N and the winding diameter. The string-like member 21 and the pressing pad 22 can be provided.
Further, in the manufacturing apparatus 2, it is possible to provide the pressing roller 13 employed in the manufacturing apparatus 1 of the first embodiment instead of the pressing pad 22.
Further, in the manufacturing apparatus 1 described in the first embodiment, the pressing pad 22 described in the manufacturing apparatus 2 can be employed instead of the pressing roller 13.
[0063]
【The invention's effect】
According to the present invention, it is possible to efficiently fill an upper space even with containers of different sizes, and to efficiently manufacture an excellent filling material that is easy to insert and remove and does not adhere to the contents at low cost. It becomes possible.
[Brief description of the drawings]
FIGS. 1A and 1B are perspective views showing an apparatus for producing an upper space filler according to an embodiment of the present invention.
2 is a perspective view showing a winding member employed in the manufacturing apparatus of FIG. 1. FIG.
FIGS. 3A to 3F are explanatory views showing manufacturing steps for carrying out the manufacturing method of the present invention using the manufacturing apparatus shown in FIG.
4A to 4D are enlarged views showing a process of forming a winding part in the manufacturing process shown in FIG.
5 is a perspective view showing another hoisting member that can be employed in the manufacturing apparatus shown in FIG. 1. FIG.
6 is a perspective view showing an upper space filler manufactured by the manufacturing apparatus shown in FIG. 1. FIG.
7 is a cross-sectional view showing a state in which the upper space filler shown in FIG. 6 is inserted into a container.
FIG. 8 is a perspective view showing an upper space filler manufacturing apparatus according to another embodiment of the present invention.
9 (a) to 9 (f) are explanatory views showing manufacturing steps for carrying out the manufacturing method of the present invention using the manufacturing apparatus shown in FIG.
FIGS. 10A to 10D are enlarged views showing a process of forming a winding part in the manufacturing process shown in FIG. 9;
[Explanation of symbols]
N cylindrical net
One end of Na net (closed end of net)
The other end of the Nb net (the open end of the net)
Nc winding part
1, 2 Upper space filler manufacturing equipment
10 Support
10a Large diameter part of support
10b Tapered portion of support
10c Small diameter part of support
11 Winding means
12 Rolling member (rigid member)
12a Curved part
13 Pressing part (Pressing roller)
21 Winding member (string member)
21a Curved part
22 Pressing part (Pressing pad)

Claims

A first step of covering a columnar support over the entire length in the axial direction with a stretchable cylindrical net having one end closed in the axial direction and the other end opened;
A second step of forming a winding portion at the open end of the net by rolling back the other end of the net toward the one end in the axial direction while expanding the other end of the net toward the outer side in the radial direction;
A third step of rolling the winding portion toward one end side in the axial direction to wind up the cylindrical net over the entire length in the axial direction, and to configure the net in a substantially lump or spherical shape. In the manufacturing method of the upper space filler of
A winding member having a curved portion for guiding the open end of the net is disposed on the outer peripheral portion of the support, and the other end of the net is guided by the curved portion so that the winding portion is formed in the second step. As described above, the third step is performed by relatively moving the curved portion at a position in contact with the other end portion of the net placed on the support to the one end side in the axial direction, and the winding portion is on the one end side in the axial direction. The curved portion is moved by relative movement from the other end side of the net toward the one end side so that the winding portion is guided by the bending portion so as to roll toward Method for manufacturing the upper space filler.

A columnar support on which a cylindrical net having elasticity that is closed at one end in the axial direction and opened at the other end is covered over the entire length in the axial direction; and a winding means for winding the net into a substantially massive or spherical shape, The winding means forms a winding portion at the open end of the net by rolling back the other end of the net toward the one end side in the axial direction while expanding the other end of the net outward in the radial direction. In the manufacturing apparatus for the upper space filler of the container configured to roll up the cylindrical net over the entire length in the axial direction so as to become a lump or a sphere by rolling toward the one end side in the axial direction ,
The hoisting means includes a hoisting member that is disposed on the outer peripheral portion of the support and has a curving portion that guides the open end of the net, and the curving portion of the member is movable relative to the support in the axial direction. Yes, the other end of the net is bent so that the winding portion is formed by moving the bent portion at a position in contact with the other end of the net covered with the support to one end side in the axial direction. And the relative movement of the bending portion from the other end side to the one end side of the net causes the winding portion to roll toward the one end side in the axial direction. An apparatus for producing an upper space filling material for a container, characterized by being guided by:

The hoisting member is made of a rigid member disposed on the outer peripheral portion of the support, and the side surface on one end side in the axial direction of the rigid member is a concave surface that functions as a curved portion, and the rigid member is axial with respect to the support The apparatus for producing an upper space filling material for a container according to claim 2 , wherein the bending portion moves in the axial direction by moving in the vertical direction.

The hoisting member is made of a flexible string-like member, and one end of the string-like member is fixed to one end portion of the support, and the string-like member is arranged in the axial direction between the support and the net covering the support. And the other end of the string-like member extends to one end in the axial direction, and the bent portion constitutes the other end of the string-like member. The apparatus for producing an upper space filling material for a container according to claim 2 , wherein the bending portion moves toward one end in the axial direction by pulling up the container toward one end in the axial direction.

The apparatus for producing an upper space filler for a container according to any one of claims 2 to 4 , wherein the plurality of hoisting members are disposed in a circumferential direction of the support.

Hoisting means comprises a pressing part that presses fixed to a support net from its outer peripheral side, the pressing portion is claims 2 to 5, characterized in that movement in the axial direction in response to axial movement of the bending portion The manufacturing apparatus of the upper space filler of the container of any one of these.

The support body has a large diameter portion on one end side in the axial direction, a small diameter portion on the other end side in the axial direction, and a taper portion positioned between the large diameter portion and the small diameter portion, and is a net covered on the support body. other end manufacturing apparatus in the upper space filler container according to any one of claims 2 to 6, characterized in that located in the small-diameter outer periphery of the.