JP4242837B2 - Buffer material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a shock absorber and a manufacturing method thereof, for example, in a shutter device, a shock absorber for a shutter device interposed between a pair of opposing support frames and both side portions of a shutter that moves in both the support frames. It relates to materials.

  Conventionally, a silencer structure as disclosed in Patent Document 1 has been proposed as a cushioning material for the shutter device as described above. That is, the sound deadening band body according to the sound deadening band structure includes a belt shaped slider and a belt shaped base made of a hard material such as hard vinyl chloride, and is bridged so that mohair hairs are planted between each other. The slider, the base, and the mohair hair are integrally formed in a substantially layered manner.

  The silencer body is attached to the guide rail via a base, and in this attached state, the slider is slidably brought into contact with the front and rear surfaces of the shutter curtain. When the shutter curtain is opened and closed, the sound deadening band structure slides the slider on the front and rear surfaces of the shutter curtain in a slippery manner, and helps to perform a smooth opening and closing operation.

  In the above-described conventional shutter device, the shutter curtain, which is a shutter, moves in all directions, such as the front-rear direction and the lateral direction, with respect to the guide rail, which is a support frame, in various situations such as swinging during opening and closing in addition to the wind. Try to move.

  On the other hand, when the shutter curtain moves in the front-rear direction, the silencer body deflects the mohair hair, which is a pile thread, between the slider and the base via the slider, and generates abnormal noise such as wind noise. It is supposed to suppress. That is, the silencer main body exhibits a cushioning function that suppresses the shaking by the action of the mohair hair against the shaking of the shutter curtain in the front-rear direction due to the breeze of the wind or the like. However, when the shutter curtain moves in the lateral direction, the slider following the shutter curtain is pulled by the mohair hair located on both sides in the moving direction, and it becomes difficult to move, and the cushion function cannot be fully exhibited.

On the other hand, when actually manufacturing a conventional silencer body, after mohair hair is planted on a slider or base, and the hair ends are aligned or raised to form a mohair material, A method of bonding a base or a slider to the mohair hair is conceivable. In addition, a method of forming a pair of mohair materials and bonding the ends of the mohair hairs to each other is also conceivable. Whichever method is employed, the mohair material must be formed once, and the manufacturing process is complicated. In addition, since the mohair hair is flexible, it is difficult to bond or align the mohair hair only with the tip of the hair, and its production is extremely difficult.
Utility Model Registration No. 2592349

The objective of this invention is providing the shock absorbing material which exhibits a suitable cushion function.
Another object of the present invention is to provide a cushioning material manufacturing method capable of easily and reliably manufacturing a cushioning material comprising a pair of base materials and pile yarns laid between the two base materials. .

In order to achieve the above object, the present invention provides a cushioning material including a pair of belt-shaped bases facing each other and a plurality of pile yarns laid between the bases. The pile yarn includes an uncut pile yarn that connects the two base materials, and a first and second cut pile yarn that are cut at an intermediate portion between the two base materials and thereby face each other across the cut portion. It is configured to include.

The present invention also provides a method for manufacturing a cushioning material. The method includes a winding step of winding a pile yarn around the surface of the endless band while circulating the endless band in a band shape, and a pair of pile yarns wound around the endless band from both sides in the width direction of the endless band. A base material supplying step for supplying the base material in the form of a belt, an adhesion step for bringing the supplied both base materials into contact with the pile yarn, and bonding both the base materials to the pile yarn using ultrasonic waves, and the endless An uncut pile yarn that connects the two base materials by cutting a pile yarn located on one of the inner and outer peripheral surfaces of the band at an intermediate portion between the two base materials and forming a cut portion in the pile yarn. If, spaced to separate a cutting step of forming the first and second cutting pi le yarns to face each other across the cutout portion, the pile yarns from the endless band through the cutout portion with the both substrates A process.

Hereinafter, a first embodiment of the present invention will be described with reference to the drawings.
First, the configuration of a shutter device that uses a shock absorber for the shutter device will be described. As shown in FIGS. 3 to 5, the shutter device includes a pair of support frames 12 that are erected on the floor surface 11, a housing 13 that is installed between upper ends of the support frames 12, and It comprises a floor surface 11, a pair of support frames 12, and a shutter 14 disposed on the inner side surrounded by a housing 13. The support frame 12 functions as a guide member. The shutter 14 functioning as a moving member is formed by connecting a plurality of blade plates 16 so as to be rotatable with respect to each other, and can be wound in a spiral shape by rotating the adjacent blade plates 16 with each other. is there. A cylindrical drum (not shown) is rotatably supported in the housing 13, and the upper end of the shutter 14 is connected to the outer peripheral surface of the drum. Then, as the drum rotates in one direction, the shutter 14 is accommodated in the housing 13 while being wound around the outer peripheral surface of the drum, so that the shutter device is opened. On the other hand, as the drum rotates in the other direction, the shutter 14 is pulled out from the housing 13 while being rewound from the outer peripheral surface of the drum, thereby closing the shutter device.

  The pair of support frames 12 are formed of a metal in a square cylinder shape, and a guide groove 15 is formed on each inner surface so as to open toward the inside of the shutter device. One of both side portions of the shutter 14 is inserted into the guide groove 15 of each support frame 12. When performing an opening / closing operation for opening or closing the shutter device, each support frame 12 supports the shutter 14 so as to reciprocate in the vertical direction while guiding the shutter 14 by the respective guide groove 15. To function. In addition, on both inner side surfaces of each guide groove 15 facing each other, receiving recesses 17 that open toward the front surface and the back surface of the shutter 14 are formed so as to extend in the longitudinal direction of the support frame 12, respectively. A pair of projecting pieces 18 project from the opening end of each housing recess 17 so that the opening of the housing recess 17 is regulated to a predetermined width. Clearances are formed between one inner surface of each guide groove 15 and the surface of the shutter 14 and between the other inner surface of the guide groove 15 and the back surface of the shutter 14. A buffer member 20 for the shutter device is housed in the housing recess 17 so as to close these gaps.

Next, the configuration of the buffer material 20 will be described.
As shown in FIG. 1 to FIG. 2E, the cushioning material 20 is flocked so as to be laid between a pair of base materials 21 having a strip shape arranged so as to face each other and the base materials 21. And a plurality of pile yarns 22.

  The base material 21 is formed of a synthetic resin film having a high waterproof property and a low dynamic friction coefficient. Examples of such synthetic resins include olefin resins such as ultra-high molecular weight polyethylene and polypropylene, amide resins such as aliphatic polyamide and aromatic polyamide, acrylic resins such as polyacryl, ester resins such as polyethylene terephthalate, fluorine Examples thereof include resins. In addition, a pair of guide protrusions 21a for positioning the pile yarn 22 extend in parallel with each other along the longitudinal direction of the base material at a predetermined interval at the intermediate portion in the width direction of each base material 21. Is provided.

  The pile yarn 22 is joined to the base material 21 between the guide protrusions 21a at the bent portion in a U-shaped state. Examples of the method for joining the pile yarn 22 to the base material 21 include adhesion using an adhesive, ultrasonic waves and the like, welding by heating, and the like, which are appropriately selected as desired. Among these, ultrasonic bonding is preferable because the base material 21 and the pile yarn 22 can be firmly bonded at the time of bonding, and the change in shape other than the bonding location can be suppressed.

  The pile yarn 22 is formed of yarns such as filament yarns and spun yarns, which are made of fibers having high durability and excellent resilience and non-water absorption. Examples of such fibers include synthetic fibers made of the synthetic resin mentioned in the substrate 21, semi-synthetic fibers made of rayon, natural fibers made of cotton, and the like. Among these, synthetic fibers made of amide resins such as olefin resins such as polypropylene, aliphatic polyamides, and aromatic polyamides are particularly preferable as fibers used for the pile yarn 22 because they are excellent in recoverability from the compressed state. . Further, when the pile yarn 22 is bonded to the base material 21 by ultrasonic bonding, it is more preferable to use a synthetic fiber similar to the synthetic resin used for the base material 21 for the pile yarn 22.

  As shown in FIGS. 4 and 5, the buffer material 20 is fixed in the guide groove 15 of the support frame 12 by inserting the first base material 21 into the housing recess 17. Further, the second base material 21 of the cushioning material 20 is supported by a pile yarn 22 protruding from the opening of the housing recess 17 and is pressed against and brought into contact with the front or back surface of the shutter 14 by the pile yarn 22. ing. And the shutter 14 is hold | maintained by both the buffer materials 20 so that it may be pinched | interposed with a pair of buffer materials 20 from the surface and the back surface.

  When the shutter 14 is opened and closed, the shutter 14 is reciprocated in the vertical direction while sliding the front and back surfaces of the shutter 14 on the second base material 21 of the cushioning material 20. At this time, since the second base material 21 is made of a synthetic resin having a low dynamic friction coefficient, the shutter 14 slides with respect to the buffer material 20, and the function of reducing the sliding resistance when the shutter is opened and closed is buffered. The material 20 exhibits.

  On the other hand, when the shutter 14 is blown by the wind when the shutter 14 is opened or closed, the shutter 14 is pressed against the second substrate 21 by shaking or rattling. At this time, the shutter 14 is received by the pile yarn 22 via the second base material 21 and is pushed back, so that the cushioning material 20 suppresses the shaking and rattling of the shutter 14.

  The single yarn fineness of the pile yarn 22 is preferably 5 to 110 dtex, more preferably 10 to 70 dtex, and still more preferably 10 to allow the resistance reducing function and the cushion function by the cushioning material 20 to be satisfactorily exhibited. 35 dtex. The normal pile yarn 22 uses a yarn (multifilament yarn) formed by twisting a plurality of fibers, and the “single yarn fineness” is a single fiber that forms the pile yarn 22. Say fineness. As the single yarn fineness is reduced, the stiffness of the pile yarn 22 decreases, and the desired cushion function cannot be fully exhibited, and there is a possibility that problems such as breakage of the pile yarn 22 may occur. As the single yarn fineness is increased, the flexibility of the pile yarn 22 is reduced, and the second base material 21 is pressed against the shutter 14 with a strong force, so that the cushioning material 20 sufficiently exhibits the resistance reducing function. This may cause a problem when the shutter 14 is opened and closed.

  The fineness of the pile yarn 22 itself is preferably 100 to 2200 dtex, more preferably 500 to 2200 dtex, and further preferably 600 to 1650 dtex. The pile yarn 22 may be a multifilament yarn or a yarn (monofilament yarn) made of one fiber. In order to satisfactorily exert the resistance reducing function and the cushion function, it is preferable to set the fineness of the pile yarn 22 itself as described above. Then, as the fineness of the pile yarn 22 is reduced, the rigidity of the pile yarn 22 is reduced, and the desired cushion function cannot be fully exhibited. As the fineness of the pile yarn 22 is increased, the flexibility of the pile yarn 22 is reduced, and the resistance reducing function cannot be sufficiently exhibited.

  The number of pile yarns 22 to be planted on the substrate 21 is preferably 1000 to 10000, more preferably 1000 to 8000, and more preferably 1500 to 1 inch per inch in the longitudinal direction of the substrate 21. 6500. As the number of pile yarns 22 piled per inch in the longitudinal direction of the base material 21 decreases, the density of the pile yarns 22 on the base material 21 decreases, and a gap is easily formed between the pile yarns 22. End up. Thus, when the density of the pile yarn 22 becomes low, the pile yarns 22 cannot support each other, the rigidity of the entire pile yarn 22 becomes low, and the shutter 14 cannot be received sufficiently. A sufficient cushion function cannot be exhibited. As the number of flocks of pile yarns 22 per inch increases, the density of the pile yarns 22 on the base material 21 increases, and the pile yarns 22 are easily clogged. When the density of the pile yarn 22 is thus increased, the flexibility of the entire pile yarn 22 is lowered, the second base material 21 is pressed against the shutter 14 with a strong force, the sliding resistance is increased, and the buffer member No. 20 cannot fully exhibit the resistance reduction function.

  As shown in FIG. 1 to FIG. 2E, some pile yarns 22, specifically, pile yarns 22 planted closer to one side than the center in the width direction of the base material 21 are both base materials 21. It is cut in the middle part between. The cut pile yarn 22 includes a first cut pile yarn 22 extending from the first base material 21 and a second cut pile yarn 22 extending from the second base material 21. The front end (cut end) of the first cut pile yarn 22 and the front end (cut end) of the second cut pile yarn 22 are opposed to each other with the cut portion 23 interposed therebetween. The cut portion 23 is provided so as to extend in the longitudinal direction of the base material 21 over the entire length of the cushioning material 20.

  The cut pile yarn 22 is opened so that the hair ends spread at the cut end. The ends of the cut pile yarns 22 swell in the lateral direction with respect to the longitudinal direction of the base material 21. Therefore, the cut pile yarn 22 is denser near the root than near the tip of the hair. The pile yarns 22 other than the cut pile yarns 22, that is, the uncut pile yarns 22 connecting the two base materials 21 swell in the lateral direction with respect to the longitudinal direction of the base materials 21 by bending between the two base materials 21. . Therefore, the non-cut pile yarn 22 is denser in the vicinity of the root than in the vicinity of the intermediate portion between the base materials 21. The entire pile yarn 22 swells in both lateral directions with respect to the longitudinal direction of the base material 21 at the central portion between the base materials 21, so that the cross-sectional shape orthogonal to the longitudinal direction of the base material 21 becomes a substantially rhombus shape. It is formed as follows. The bent portion of the uncut pile yarn 22 is more easily bent than the straight hair.

  When an external force is applied to the pile yarn 22 through the second base material 21 in accordance with the movement of the shutter 14, when the pile yarn 22 is crushed and compressed, the pile yarn 22 returns to its original shape. To produce repulsive force. The cushion function of the cushioning material 20 is brought about by the repulsive force of the pile yarn 22. However, when the second substrate 21 is excessively pressed against the shutter 14 as the repulsive force of the pile yarn 22 increases, the sliding resistance of the shutter 14 against the buffer material 20 increases, and the resistance reducing function by the buffer material 20 is increased. It becomes impossible to demonstrate. Therefore, in the present embodiment, by providing the cut portion 23, the cushioning material 20 appropriately exhibits a cushion function and a resistance reduction function depending on the situation. Specifically, the cushioning material 20 exerts a good balance between the cushion function and the resistance reduction function when the applied external force is relatively weak, and prioritizes the cushion function over the resistance reduction function when the applied external force is relatively strong. To do. When the shutter 14 swings as the shutter 14 is opened and closed, the external force applied to the cushioning material 20 is relatively weak. When the shutter 14 is blown by the wind, the external force applied to the cushioning material 20 is relatively strong.

  That is, when a relatively weak external force is applied to the cushioning material 20 as the shutter 14 moves in the front-rear direction, the non-cut pile yarn 22 becomes arcuate so that the whole is curved almost uniformly and rebounds. Generate power. On the other hand, in the cut pile yarn 22, one hair tip of the first cut pile yarn 22 and the second cut pile yarn 22 facing each other across the cut portion 23 enters between the other hair tips. For this reason, the cut pile yarn 22 does not generate a repulsive force. Accordingly, the repulsive force applied to the shutter 14 from the entire pile yarn 22 is reduced. As a result, when the applied external force is relatively weak, the cushioning material 20 generates only a repulsive force commensurate with the external force, exhibits a necessary and sufficient and appropriate cushion function, and suppresses the shaking of the shutter 14. At the same time, noises such as rattling noises that occur when the shutter 14 is opened and closed are suppressed. Further, since the shock absorbing material 20 generates only a repulsive force corresponding to the external force, the cushioning function and the resistance reducing function are exhibited in a well-balanced manner, so that the opening / closing operation of the shutter 14 is performed without any trouble.

  On the other hand, when the external force applied to the buffer material 20 is relatively strong, one of the hair ends of the first cut pile yarn 22 and the second cut pile yarn 22 facing each other with the notch 23 interposed therebetween is the other cut pile yarn 22. Go deep in between. At this time, since the cut pile yarn 22 becomes denser as it approaches its root, one of the first and second cut pile yarns 22 is easily caught by the other pile yarn 22, and resistance when the cut pile yarn 22 enters. Will increase. Alternatively, the hair end of the cut pile yarn 22 contacts the base material 21. Then, the cut pile yarn 22 is bowed like the non-cut pile yarn 22, and the whole is bent almost uniformly to generate a repulsive force. As the external force applied to the cushioning material 20 increases, the resistance when one of the first and second cut pile yarns 22 facing each other enters the other increases, or the number of the cut pile yarns 22 that are caught with each other increases. The repulsive force generated by the cut pile yarn 22 increases. Therefore, when the applied external force is relatively strong, the cushioning material 20 gives priority to the cushion function over the resistance reduction function and generates a strong repulsive force that can sufficiently receive the strong external force. . As a result, the buffer material 20 suppresses a large movement of the shutter 14 and suppresses the generation of a large abnormal noise such as a wind noise.

  Actually, a pile yarn 22 made of polypropylene and having a fineness of 1350 dtex / 52 filaments is used, the number of flocks per inch in the longitudinal direction of the base material 21 is 1800, and the distance between the base materials 21 is 7 mm. Thus, the buffer material 20 having a length of 10 cm was formed. Then, the buffer material 20 was compressed in the direction in which the pile yarn 22 extends (direction in which the interval between the base materials 21 is narrowed), and the repulsive force generated by the buffer material 20 was measured. As a result, the repulsive force increased linearly in proportion to the compression force until the compression amount became 2 mm. Moreover, when the amount of compression exceeded 2 mm, the repulsive force increased in a curve more than the amount commensurate with the compressive force.

  In addition, when the shutter 14 moves in the lateral direction, as shown in FIGS. 6A and 6B, one of the first and second cut pile yarns 22 facing each other with the notch 23 as a boundary is On the other hand, the position is shifted in the lateral direction (the left-right direction in FIGS. 6A and 6B). For this reason, the second base material 21 can flexibly follow the movement of the shutter 14, and the cushioning material 20 always maintains the state in which the shutter 14 is in contact with the second base material 21. Therefore, the cushioning material 20 flexibly responds to any movement of the shutter, and sufficiently exhibits the cushion function and the resistance reduction function.

Next, the configuration of a manufacturing apparatus for manufacturing the buffer material 20 will be described.
As shown in FIGS. 7A and 7B, the manufacturing apparatus includes an endless band 51 formed by connecting both ends of a band-shaped member. The endless band 51 extends around the plurality of rollers 52. Further, in the drawing, when the left side is the start end side and the right side is the end side, the endless band 51 is rotated in the manufacturing apparatus as the start end side roller 52 is rotated by the rotation driving device 53. Between the starting end side roller 52 and the terminating end roller 52, a pile yarn supplying unit 54, a base material supplying unit 55, an adhesive unit 56, a cutting unit 57, and a collecting unit 58 are sequentially provided from the starting end side to the terminating end side. Is provided.

  The pile yarn supply unit 54 includes a pair of bobbins 59 facing each other with the endless band 51 interposed therebetween. Both bobbins 59 are configured to rotate around an axis extending along the extending direction of the endless band 51 while supplying the pile yarn 22 to the surface of the endless band 51. The base material supply unit 55 includes a pair of supply drums 60 facing each other with the endless band 51 interposed therebetween. Each supply drum 60 accommodates the base material 21 in a wound state, and the base material 21 drawn out from each supply drum 60 is supplied to the left and right sides of the endless band 51 so as to sandwich the endless band 51. And is configured to move in parallel with the endless band 51.

  The bonding portion 56 includes a pair of horns 61 for transmitting ultrasonic vibrations to the base materials 21 and a pair of pressing members 62 for pressing the base materials 21 toward the endless band 51. Each horn 61 is paired with one of the pressing members 62. The pairs of horns 61 and pressing members 62 corresponding to the horns 61 are arranged so as to be alternately arranged with respect to the circumferential direction of the endless band 51 with the endless band 51 interposed therebetween. That is, the first horn 61 is opposed to the first pressing member 62, and the second horn 61 is opposed to the second pressing member 62. The cutting portion 57 includes a cutting blade 63 that faces one of the inner and outer peripheral surfaces of the endless band 51. In FIG. 7A and FIG. 7B, the cutting blade 63 faces the inner peripheral surface of the endless band 51. The cutting blade 63 is disposed at the center of the endless band 51 in the width direction. The collection unit 58 includes a collection drum 64 disposed on one side of the endless band 51, and the produced cushioning material 20 is wound on the collection drum 64 and collected.

Next, the manufacturing method of the shock absorbing material 20 using the said manufacturing apparatus is demonstrated.
The buffer material 20 is manufactured through a winding process, a base material supply process, an adhesion process, a cutting process, and a separation process.

  The winding step is performed to wind the pile yarn 22 around the surface of the endless band 51, and is performed by the pile yarn supply unit 54 of the manufacturing apparatus. In the pile yarn supply unit 54, a pair of bobbins 59 rotate around the endless band 51 and supply the pile yarn 22 onto the endless band 51. The pile yarn 22 supplied onto the endless band 51 is spirally wound around the surface of the endless band 51 and moves toward the terminal end together with the endless band 51.

  The base material supply step is performed to supply the base material 21 from both the left and right sides of the endless band 51 to the pile yarn 22 wound around the endless band 51, and is performed by the base material supply unit 55 of the manufacturing apparatus. Is done. In the base material supply section 55, the base material 21 drawn out from both supply drums 60 is supplied so as to be positioned on both sides of the endless band 51. At this time, the pile yarn 22 wound around the endless band 51 is positioned between the pair of guide protrusions 21 a provided on each base material 21.

  The bonding step is performed to bring the supplied base materials 21 into contact with the pile yarns 22 and to bond the pile yarns 22 to the base materials 21 using ultrasonic waves, and is performed at the bonding portion 56 of the manufacturing apparatus. Is done. In the adhesive portion 56, the two horns 61 are pressed from the other side of the endless band 51 while pressing the one substrate 21 from one side of the endless band 51 by each of the pressing members 62 to contact the pile yarn 22. Each is brought into contact with the other substrate 21. Both horns 61 transmit ultrasonic vibrations to both base materials 21, and both the base materials 21 and pile yarns 22 are bonded to each other by the ultrasonic vibrations.

  The cutting step is performed to cut the pile yarn 22 located on one of the inner and outer peripheral surfaces of the endless band 51 at an intermediate portion of both base materials 21 to form a cut portion 23, and the cutting portion of the manufacturing apparatus. 57. In the cutting part 57, the center of the lower half part of the pile yarn 22 wound around the endless band 51 is cut by the cutting blade 63 facing the inner peripheral surface of the endless band 51. As a result, the cushioning material 20 having the cut portions 23 is manufactured so as to cover the endless band 51.

  The separation step is performed to separate the pile yarn 22 from the endless band 51 together with the pair of base materials 21 through the cut portion 23, and is performed by the collection unit 58 of the manufacturing apparatus. In the recovery unit 58, the cushioning material 20 on the endless band 51 is pulled upward by the rotation of the recovery drum 64 or the manual operation of the operator. Then, the first and second cut pile yarns 22 facing each other with the notch 23 interposed therebetween are curved and the notch 23 expands, whereby the cushioning material 20 is pulled out from the endless band 51, and the endless Separated from the band 51. Then, the manufactured cushioning material 20 is wound on the collection drum 64 and collected.

The advantages exhibited by the above embodiment are described below.
The cushioning material 20 according to the present embodiment includes a pair of base materials 21 and a pile yarn 22 laid between the base materials 21. A part of the pile yarn 22 is cut at an intermediate portion between the two base materials 21, thereby forming first and second cut pile yarns 22 that face each other with the cut portion 23 interposed therebetween. By providing the cut portion 23, the pile yarn 22 exhibits an appropriate cushion function and resistance reduction function in a balanced manner against a relatively weak force such as shaking when the shutter 14 is opened and closed. In addition, the cushion function is preferentially exerted against a relatively strong force such as wind swell. In addition, even when the shutter 14 rolls or the like, the first and second cut pile yarns 22 are laterally displaced from each other with the cut portion 23 as a boundary corresponding to the movement of the shutter 14, thereby causing the second base material 21. In this state, the shutter 14 is kept in contact. For this reason, it can respond flexibly with respect to the movement of the shutter 14, and can sufficiently exhibit a cushion function for suppressing the shaking of the shutter 14.

  The pile yarn 22 is formed so that the cross-sectional shape orthogonal to the longitudinal direction of both the base materials 21 forms a substantially rhombus shape. For this reason, a part of the pile yarn 22 (non-cut pile yarn 22) is curved against a relatively weak external force applied to the cushioning material 20 from the shutter 14, so that the cushion function and the opening and closing of the shutter 14 are favorable. The intended resistance reduction function can be achieved in a balanced manner. Furthermore, against the relatively strong external force applied from the shutter 14 to the cushioning material 20, the entire pile yarn 22 (the cut pile yarn 22 and the non-cut pile yarn) is curved so that the cushion function is preferentially exerted, The movement of the shutter 14 can be suppressed, and the generation of abnormal noise such as wind noise can be suppressed.

  The cushioning material 20 includes a winding step of winding the pile yarn 22 around the surface of the endless band 51, a substrate supply step of supplying both base materials 21 from both sides of the pile yarn 22, and both the base materials 21 and the pile yarn 22 by ultrasonic waves. And a cutting process in which a part of the pile yarn 22 is cut to form a cut portion 23. Further, the manufactured cushioning material 20 is separated from the endless band 51 via the notch 23 and collected in the separation step. For this reason, the shock absorbing material 20 is manufactured almost automatically by the use of the manufacturing apparatus without particularly performing complicated work. Accordingly, the cushioning material 20 including the pair of base materials 21 and the pile yarns 22 laid between the base materials 21 can be easily and reliably manufactured.

  FIG. 8 shows an example in which the cushioning material 20 is applied as a support member for supporting both sides of the door or window screen 70. The cushioning material 20 is attached to both side frames 71 (only one side frame is shown in FIG. 8) of doors and windows. The side frame 71 which is a guide member has a guide groove 72 extending in the vertical direction (a direction orthogonal to the paper surface of FIG. 8), and receiving grooves 73 extending in the vertical direction are formed on both inner side surfaces of the guide groove 72 facing each other. Each is formed. The cushioning material 20 is fixed to the guide groove 72 of the side frame 71 by inserting the base materials 21 into the housing recesses 73.

  A side portion of the screen 70 which is a moving member is located in the guide groove 72, and the screen 70 can be moved up and down along the guide groove 72. A side portion of the screen 70 is inserted into the cut portion 23 of the cushioning material 20. The first cut pile yarn 22 and the second cut pile yarn 22 that are opposed to each other with the notch 23 interposed therebetween sandwich the side portion of the screen 70 and support the screen 70 from the front surface and the back surface thereof. Therefore, the screen 70 moves up and down while sliding on the cut pile yarn 22 with both sides thereof held by the cushioning material 20. The cut pile yarn 22 exhibits a good cushion function so as to prevent the screen 70 from swinging in the front-rear direction (vertical direction in FIG. 8). On the other hand, the uncut pile yarn 22 of the cushioning material 20 receives a side edge of the screen 70 and has a good cushion function so as to suppress the screen 70 from swinging in the width direction (left-right direction in FIG. 8). Demonstrate.

  As described above, the cushioning material 20 is not limited to application to the shutter device, but can also be applied as a support member for the screen 70. The buffer material 20 is not limited to the screen 70 and can be applied as a support member for various sheet-like members or plate-like members such as glass and panels. In this case, the buffer material 20 can be applied to a fixed sheet-like member or plate-like member, or a slidable sheet-like member or plate-like member. Moreover, the buffer material 20 may be attached to the peripheral part of a mesh-shaped screen. In this case, the tip of the cut pile yarn 22 in the cushioning material 20 functions to prevent the small animals such as insects from entering by engaging the mesh of the screen.

Next, a second embodiment of the present invention will be described with reference to FIGS. 9 to 11 (c), focusing on differences from the first embodiment of FIGS.
As shown in FIG. 9, the cushioning material 120 of the present embodiment is different from the cushioning material 20 of FIG. 1 in that a film 80 is constructed between both base materials 21. The film 80 is arranged at the center in the width direction of both base materials 21 and extends along the longitudinal direction of the base material 21 over the entire length of the cushioning material 120. The cut pile yarn 22 is disposed on one side of the film 80, and the non-cut pile yarn 22 is disposed on the other side of the film 80.

  The film 80 is made of a material excellent in durability, resilience and non-water absorption, preferably a polypropylene sheet material. The thickness of the film 80 is selected according to the purpose of use of the cushioning material 120. When the cushioning material 120 mainly requires flexibility, a relatively thin film 80 is used. When the cushioning material 120 requires load resistance, a relatively thick film 80 is used. Is done.

  When the cushioning material 120 having the film 80 is applied to the shutter device shown in FIG. 4 instead of the cushioning material 20 of FIG. 1 that does not have the film 80, the following advantages are obtained. That is, the cushioning material 120 provided with the film 80 has a stronger repulsive force (elastic force) than the cushioning material 20 not provided with the film 80, and has a high shielding performance against liquids and foreign matters. Therefore, in a situation where the buffer material receives a relatively large load from the shutter 14 of the shutter device, it is desirable to apply the buffer material 120 including the film 80 to the shutter device. Furthermore, when the cushioning material 120 provided with the film 80 is applied to the shutter device, it is possible to suitably prevent wind and rain, dust and the like from entering the inside of the support frame 12 of the shutter device. Further, since the film 80 is disposed at the center in the width direction of the cushioning material 120, the cushioning material 120 is deformed in a well-balanced manner with respect to the received load, thereby exhibiting a good cushion function and resistance reduction function.

  FIG. 10 shows an example in which the cushioning material 120 of FIG. 9 is applied as a support member for the glass 90 in the sliding window. The cushioning material 120 is attached to the lower frame 91 of the sliding window so that the cut portion 23 faces upward. The lower frame 91 serving as a guide member has guide grooves 92 extending in a horizontal direction (a direction orthogonal to the paper surface of FIG. 10), and both base materials 21 of the cushioning material 120 are provided on both inner surfaces of the guide grooves 92 facing each other. It is fixed. The connecting positions of the pile yarns 22 with respect to both the base materials 21 are shifted from the center in the width direction of both the base materials 21 so that the uncut pile yarn 22 contacts the inner bottom surface of the guide groove 92.

  The lower end portion of the glass 90 that is a moving member is located in the guide groove 92, and the glass 90 can move in the horizontal direction along the guide groove 92. The lower end portion of the glass 90 is inserted into the cut portion 23 of the cushioning material 120. The first cut pile yarn 22 and the second cut pile yarn 22 that are opposed to each other with the notch 23 interposed therebetween sandwich the lower end portion of the glass 90 and support the glass 90 from the front surface and the back surface thereof. Therefore, the glass 90 moves while sliding on the cut pile yarn 22 with its lower end held by the cushioning material 120. The cut pile yarn 22 exhibits a good cushion function so as to prevent the glass 90 from swinging in the front-rear direction (left-right direction in FIG. 10).

  On the other hand, the film 80 receives the lower edge of the glass 90. The film 80 is preferably a polypropylene sheet material having a relatively large thickness, for example, a thickness larger than the thickness of the pile yarn 22 so as to withstand the load received from the glass 90. The uncut pile yarn 22 that exists between the inner bottom surface of the guide groove 92 and the film 80 functions together with the film 80 as a cushion that receives the force in the vertical direction. Therefore, the glass 90 is preferably prevented from swinging in the vertical direction, and the impact in the vertical direction is preferably mitigated.

  The cushioning material 120 of FIG. 9 provided with the film 80 is not limited to the glass 90 like the cushioning material 20 of FIG. It can be applied as a supporting member for the sheet-like member or plate-like member. In this case, the sheet-like member or plate-like member may be fixedly arranged or slidable.

  Fig.11 (a)-FIG.11 (c) show the outline | summary of the manufacturing apparatus for manufacturing the shock absorbing material 120 of FIG. The manufacturing apparatus shown in FIGS. 11 (a) and 11 (b) is configured by adding a film supply unit 65 to the manufacturing apparatus shown in FIGS. 7 (a) and 7 (b). The film supply unit 65 is disposed on the upstream side of the pile yarn supply unit 54. The film supply unit 65 includes a spool 66 that accommodates the film 80 in a wound state. The film 80 unwound from the spool 66 is supplied to the outer peripheral surface of the endless band 51 and is supplied to the pile yarn supply unit 54 together with the endless band 51.

  The shock-absorbing material 120 is manufactured through the film supply process, the winding process, the base material supply process, the adhesion process, the cutting process, and the separation process. The film supply process is performed by the film supply unit 65 in order to supply the film 80 to the outer peripheral surface of the endless band 51. The film 80 unwound from the spool 66 is supplied to the outer peripheral surface of the endless band 51 and covers the outer peripheral surface of the endless band 51 (see FIG. 11C).

  In the next winding step, the pile yarn 22 supplied from the pair of bobbins 59 is wound around the endless band 51 covered with the film 80. (Refer FIG.11 (c)). Thereafter, in the same manner as the procedure shown in FIGS. 7A and 7B, the base material supplying step, the adhering step, the cutting step, and the separating step are performed. In particular, in the bonding step, both the base material 21, the pile yarn 22, and the film 80 are bonded to each other by the ultrasonic vibration generated by the two horns 61.

Next, a third embodiment of the present invention will be described with reference to FIGS. 12 to 15 (c), focusing on differences from the second embodiment of FIGS. 9 to 11 (c).
As shown in FIG. 12, the cushioning material 220 of this embodiment includes a film 80 that is laid between both base materials 21, similarly to the cushioning material 120 of FIG. 9. However, in the present embodiment, the point that the film 80 is provided outside the pile yarn 22 is different from the cushioning material 120 of FIG. 9. The film 80 covers the uncut pile yarn 22 on the opposite side of the cut portion 23.

  FIG. 13 shows an example in which the cushioning material 220 of FIG. 12 is applied to a shutter device. The cushioning material 220 is attached to the support frame 12 so that the cut portion 23 faces the inside of the support frame 12 of the shutter device, in other words, the film 80 faces the outside of the support frame 12. Since the film 80 is disposed on the outside, a higher shielding effect is exhibited as compared with the case where the cushioning material 120 of FIG. 9 is applied to the shutter device. Further, since the pile yarn 22 is shielded from the external space of the support frame 12 by the film 80, the pile yarn 22 is prevented from being soiled.

  FIG. 14 shows an example in which the cushioning material 220 of FIG. 12 is applied to a ventilation system. The ventilation system includes a blower device 95 and a duct 96 extending from the blower device 95. The buffer material 220 is provided between the blower device 95 and the duct 96, and connects the blower device 95 and the duct 96 in an airtight state. One base material 21 is attached to the blower device 95, and the other base material 21 is attached to the duct 96. The film 80 is disposed so as to face outward.

  The blower device 95 generates an air flow with the duct 96 by the operation of a motor (not shown) provided in the blower device 95. The cushioning material 220 including the film 80 prevents air leakage between the blower device 95 and the duct 96, and forms an airtight space between the blower device 95 and the duct 96. Further, the cushioning material 220 allows relative movement between the blower device 95 and the duct 96, and suppresses vibration generated by the motor from being transmitted from the blower device 95 to the duct 96. That is, the buffer material 220 preferably functions as an airtight seal and a vibration damper.

  FIG. 15A to FIG. 15C show an outline of an apparatus for manufacturing the cushioning material 220 of FIG. In the manufacturing apparatus shown in FIGS. 15A and 15B, the film supply unit 65 is disposed between the pile yarn supply unit 54 and the base material supply unit 55. It is different from the manufacturing apparatus shown in 11 (b).

  The buffer material 220 is manufactured through a film supply process after the winding process, and a base material supply process, an adhesion process, a cutting process, and a separation process. In the film supply process, the film 80 is supplied from the outer peripheral side of the endless band 51 to the pile yarn 22 wound around the endless band 51 in the winding process. The film 80 unwound from the spool 66 of the film supply unit 65 covers the pile yarn 22 located on the outer peripheral surface of the endless band 51 (see FIG. 15C).

  In the next base material supplying step, the base material 21 drawn out from both the supply drums 60 is supplied so as to be located on both sides of the endless band 51. At this time, the corresponding side portions of the endless band 51 are aligned between the pair of guide protrusions 21 a provided on each base material 21, and both side edges of the film 80 wrap the pile yarn 22 on the endless band 51. In this way, it is bent (see FIG. 15C). Thereafter, the adhesion process, the cutting process, and the separation process are performed in the same manner as the procedure shown in FIGS.

Each of the above embodiments can be modified and embodied as follows.
As shown in FIG. 16A to FIG. 16C, the connection buffer material 300 may be formed by connecting two buffer materials 20 of FIG. 1. The connection buffer material 300 is formed by connecting adjacent base materials 21 of two buffer materials 20 arranged in parallel. The adjacent base materials 21 are connected to each other by using an adhesive member 301 such as an adhesive tape or a typer (Typar: registered trademark of DuPont).

  In FIG. 16A, the two cushioning members 20 are connected so that the cut portions 23 are oriented in the same direction. In FIG. 16B, the two cushioning materials 20 are connected so that the cut portions 23 are opposite to each other (toward the outside). In FIG.16 (c), the two shock absorbing materials 20 are connected so that the notch part 23 may mutually oppose (facing inside).

  FIG. 17 shows an example in which the coupling buffer material 300 of FIG. 16A is applied to a shutter device. Since the connection buffer material 300 contacts the shutter 14 in a wide area, the vibration and vibration of the shutter 14 are more preferably mitigated as compared with the case where the buffer material 20 of FIG. 1 is used. Of course, it is also possible to apply the coupling cushioning material 300 of FIGS. 16B and 16C to the shutter device. Which of the coupling buffer materials 300 in FIGS. 16A to 16C is used can be appropriately selected according to the type of the shutter device, the installation environment of the shutter device, and the like.

  Note that, although not particularly illustrated, each of the coupling cushioning materials 300 in FIGS. 16A to 16C is configured by coupling two cushioning materials 120 in FIG. 9 or two cushioning materials 220 in FIG. It may be formed by connecting them together. In this case, the coupling cushioning material 300 can be suitably used not only for the shutter device but also for a device requiring airtightness such as a ventilation system as shown in FIG.

  Further, each of the coupling cushioning materials 300 in FIGS. 16A to 16C includes any two of the cushioning material in FIG. 1, the cushioning material 120 in FIG. 9, and the cushioning material 220 in FIG. 12. It may be formed by connecting.

  Weather resistance may be imparted to at least one of the base material 21 and the pile yarn 22. As a method for imparting weather resistance, a method of kneading a weathering agent into a synthetic resin used for both the base material 21 or the pile yarn 22, or coating both the base material 21 or the pile yarn 22 with a processing liquid containing a weathering agent, etc. Is mentioned. Examples of the weathering agent include hindered amine light stabilizers and benzotriazole ultraviolet absorbers. When comprised in this way, durability of both base materials or a pile thread | yarn can be improved. In the cushioning materials 120 and 220 provided with the film 80, weather resistance may be imparted to the film 80 in the same manner as described above.

The substrate 21 is not limited to a film, and may be formed of, for example, a synthetic resin woven fabric, knitted fabric, non-woven fabric, or sheet.
The shutter device is not limited to a type that opens and closes in the vertical direction, but may be a type that opens and closes in the horizontal direction such as the front-rear direction and the left-right direction, or a type that opens and closes in the front-rear direction and then opens and closes in the vertical direction.

  A pressure sensitive adhesive such as rubber or acrylic is applied to the back surface of the first substrate 21 fixed to each support frame 12 in the shutter device, or a pressure sensitive adhesive is applied to both sides of the core material. You may form a sticking layer by sticking a double-sided adhesive tape. And you may affix the buffer material 20 on the inner bottom face of the accommodation recessed strip 17 through the said sticking layer. Alternatively, the housing recess 17 or the guide groove 15 may be omitted, the support frame 12 may be formed, and the cushioning material 20 may be attached to a predetermined portion of the support frame 12 via an adhesive layer. Of course, in the application of the cushioning material to other than the shutter device, the base material 21 may be stuck to the object via the sticking layer.

  In the manufacturing method of each of the above embodiments, the cushioning material 20 (120, 220) is separated from the endless band 51, and then wound on the collection drum 64 and collected. However, the present invention is not limited to this, and after the buffer material 20 (120, 220) is manually pulled out from the endless band 51 and separated, the desired length without winding the buffer material 20 (120, 220) as it is. You may cut | disconnect in length and collect | recover in the state which makes | forms linear form. When comprised in this way, the collection | recovery drum 64 can be abbreviate | omitted and the structure of a manufacturing apparatus can be simplified.

The perspective view of the shock absorbing material in 1st Embodiment of this invention. The front view of a buffer material. The rear view of a buffer material. The top view of a shock absorbing material. The right view of a shock absorbing material. The left view of a buffer material. The partially broken front view of a shutter apparatus. The cross-sectional view which shows the state which attached the shock absorbing material to the support frame. The sectional side view which shows the state which attached the shock absorbing material to the support frame. The front view which shows the state in which the pile thread | yarn shifted laterally in the notch part. The front view which shows the state in which the pile thread | yarn shifted laterally in the notch part. The conceptual diagram which shows the state which looked at the manufacturing apparatus of the buffer material of FIG. 1 from the plane. The conceptual diagram which shows the state which looked at the manufacturing apparatus of the buffer material of FIG. 1 from the side. Sectional drawing which shows the example which applied the buffer material of FIG. 1 as a supporting member for screens. The front view of the shock absorbing material in 2nd Embodiment of this invention. Sectional drawing which shows the example which applied the buffer material of FIG. 9 as the supporting member for glass in a sliding window. The conceptual diagram which shows the state which looked at the manufacturing apparatus of the shock absorbing material of FIG. 9 from the plane. The conceptual diagram which shows the state which looked at the manufacturing apparatus of the buffer material of FIG. 9 from the side. Sectional drawing for demonstrating the manufacturing process of the shock absorbing material of FIG. The front view of the shock absorbing material in 3rd Embodiment of this invention. Sectional drawing which shows the example which applied the shock absorbing material of FIG. 12 to the shutter apparatus. Sectional drawing which shows the example which applied the shock absorbing material of FIG. 12 to the ventilation system. The conceptual diagram which shows the state which looked at the manufacturing apparatus of the shock absorbing material of FIG. 12 from the plane. The conceptual diagram which shows the state which looked at the manufacturing apparatus of the buffer material of FIG. 12 from the side. Sectional drawing for demonstrating the manufacturing process of the shock absorbing material of FIG. The front view which shows the connection shock absorbing material formed by connecting two shock absorbing materials of FIG. The front view which shows the connection shock absorbing material formed by connecting two shock absorbing materials of FIG. The front view which shows the connection shock absorbing material formed by connecting two shock absorbing materials of FIG. Sectional drawing which shows the example which applied the connection buffer material of Fig.16 (a) to the shutter apparatus.

Claims (21)

In a cushioning material comprising a pair of strip-shaped base materials facing each other and a plurality of pile yarns laid between the two base materials,
The pile yarn is cut at an intermediate portion between the base materials and the uncut pile yarn connecting the base materials, and the first and second are formed so as to face each other with the cut portion interposed therebetween. A cushioning material comprising a cut pile yarn.   The cushion material according to claim 1, wherein the pile yarn bulges on both sides in the width direction of the two base materials, and the degree of the bulge increases toward an intermediate portion between the two base materials.   The cushioning material according to claim 1 or 2, wherein the pile yarn disposed closer to one side than the center in the width direction of the two base materials is cut at an intermediate portion between the two base materials.   4. The cushioning material according to claim 1, wherein the pile yarn has 1000 to 10,000 flocks per inch in the longitudinal direction of the base material. 5.   The cushioning material according to any one of claims 1 to 4, wherein weather resistance is imparted to the base material or the pile yarn.   The cushion material according to any one of claims 1 to 5, wherein the pile yarn has a single yarn fineness of 5 to 110 dtex.   The buffer material according to any one of claims 1 to 5, wherein the pile yarn is formed from a multifilament yarn or a monofilament yarn, and has a fineness of 100 to 2200 dtex.   The shock-absorbing material according to any one of claims 1 to 7, further comprising a film provided between the base materials so as to extend along a longitudinal direction of the base materials.   The cushioning material according to claim 8, wherein the film is disposed substantially at the center in the width direction of both base materials.   The cushioning material according to claim 9, wherein the first and second cut pile yarns are disposed on one side of the film, and the uncut pile yarn is disposed on the other side of the film.   The cushioning material according to claim 8, wherein the film is provided outside the pile yarn.   The cushioning material according to claim 11, wherein the film covers an uncut pile yarn on the opposite side of the cut portion.   The cushioning material according to any one of claims 8 to 11, wherein the film is made of a sheet material made of polypropylene. Using a buffer member according to any one of claims 8 to claim 13, the buffer material, disposed between two air-tight space forming member connected together to form an airtight space, the one the substrate is attached to one of the airtight space forming member, use of the other substrate buffer material you attached to the other airtight space forming member. Using a buffer member according to any one of claims 1 to 13, the buffer material, disposed between the guide member and the movable member movable along the guide member, wherein both substrate One of them is attached to the guide member, and the other is a method of using a cushioning material in contact with the moving member. The shock-absorbing material according to any one of claims 1 to 13, wherein the shock-absorbing material is disposed between the guide member and a sheet-like or plate-like moving member movable along the guide member. And the both base materials are attached to the guide member, and the cut portion is a method of using a cushioning material that receives the edge of the moving member. The cushioning material according to any one of claims 1 to 13, wherein the cushioning material is mounted on an edge of a sheet-like or plate-like member, and the cut portion is an edge of the sheet-like or plate-like member. How to use cushioning material that accepts parts. A pair of support frames facing each other and a shutter supported by both support frames so as to be movable along the both support frames, the shutter being windable at one end thereof, In each shutter device supported by a corresponding one of both support frames, Wherein with the placed that slow衝材between the two support frames each said shutter side corresponding to that of,
The shock-absorbing material includes a pair of strip-shaped base materials facing each other, and a plurality of pile yarns laid between the two base materials,
One of the base materials is attached to each support frame, the other is in contact with the shutter,
The pile yarn includes an uncut pile yarn that connects the two base materials, and a first and second cut pile yarn that are cut at an intermediate portion between the two base materials and thereby face each other across the cut portion. A shutter device comprising: a shutter device ; A method of manufacturing a cushioning material,
A winding process in which a pile yarn is wound around the surface of the endless band while rotating the endless band in a band shape;
A base material supplying step for supplying a base material forming a pair of belt shapes from both sides in the width direction of the endless band, with respect to the pile yarn wound around the endless band,
An adhesion step in which the supplied base materials are brought into contact with the pile yarn, and the both base materials are bonded to the pile yarn using ultrasonic waves;
Uncut cutting the pile yarn located on one of the inner and outer peripheral surfaces of the endless band at an intermediate portion between the two base materials, forming a cut portion in the pile yarn, and connecting the two base materials A cutting step of forming the pile yarn and the first and second cut pile yarns facing each other across the cut portion ;
And a separation step of separating the pile yarn from the endless band together with the base materials through the cut portion.   Prior to the winding step, a film supply step of supplying a film to the peripheral surface of the endless band opposite to the side where the pile yarn to be cut in the cutting step is located, and covering the peripheral surface with the film The manufacturing method according to claim 19, further comprising: bonding the pile yarn and the film to the two base materials in the bonding step.   Between the winding step and the base material supplying step, a film is supplied to the peripheral surface of the endless band on the side opposite to the side where the pile yarn to be cut in the cutting step is located. The manufacturing method according to claim 19, further comprising a film supply step of covering the upper pile yarn with a film, wherein the pile yarn and the film are bonded to the both substrates in the bonding step.

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