JP4532205B2 - Foaming roller crushing method and apparatus and foaming roller manufacturing method - Google Patents

Description

  The present invention relates to a foaming roller crushing method and apparatus, and a foaming roller manufacturing method, and more particularly to a core material and a core widely used in electrophotographic apparatuses and electrostatic recording apparatuses such as copying machines, laser printers, and facsimiles. The present invention relates to a crushing method and apparatus for rupturing a bubble film in a foam layer of a foam roller having a cylindrical foam layer formed on the outer periphery of a material to form a continuous cell structure, and a method for producing a foam roller.

The crushing process is a process performed to break the cell membrane (cell) of the foamed molded product and stabilize the hardness and air flow rate of the foamed molded product. There is a roll crushing system that ruptures a film (for example, see Patent Document 1). The roll crushing method is a method in which a foam film is ruptured by passing and pressurizing a foam molded body between a pair of rolls. In order to obtain a good crushing, as shown in FIG. It passed between the plurality of rolls 11 that were paired up and down (for example, Patent Document 2). In this case, the pair of upper and lower rolls 11 are installed with the interval gradually narrowed along the feeding direction (traveling direction) of the foam molded body 10 to prevent the foam molded body 10 from being cracked by the crushing process.
Japanese Patent Application Laid-Open No. 07-053758 JP 2000-158548 A

  However, the above-described method is to crush the foamed molded article by simply passing between the rolls along the traveling direction, and it is difficult to crush a cylindrical shape like a foaming roller over the entire area. It was necessary to change the contact position with the roll pair and to pass between the roll pairs several times or to pass a plurality of roll pairs. In the case of using a plurality of roll pairs, there is a problem that the equipment becomes huge.

  Further, when the foam layer of the foam roller is in contact with the roll pair, a crack may occur because a sudden force is applied to the foam layer.

  Therefore, the present invention realizes good crushing of a cylindrical foaming roller having a core material and a cylindrical foam layer formed on the outer periphery of the core material, and realizes downsizing of equipment. Another object of the present invention is to provide an apparatus and a method for producing a foam roller.

The foaming roller crushing method of the present invention, which has achieved the above object, rotates in the same direction in the foaming roller crushing method having a core material and a cylindrical foam layer formed on the outer periphery of the core material. Between the pair of rolls arranged in parallel, the foaming roller is arranged parallel to the pair of rolls, and the spacing between the foaming roller and the pair of rolls or the spacing between the pair of rolls is continuously or The foaming roller is pressed stepwise by one pair of the rolls while being changed stepwise.

Moreover, crushing apparatus of the present invention has achieved the above object, a core material, the crushing apparatus of the foam roller having a cylindrical foam layer formed on the outer periphery of the core material, arranged in parallel 1 A pair of rolls; means for rotationally driving the pair of rolls in the same direction; means for varying the interval between the pair of rolls; means for rotatably fixing both ends of the core of the foam roller; A means for transferring the roller between the pair of rolls, and fixing the both ends of the core of the foaming roller to be rotatable by the fixing means; By arranging and changing the interval between the roll pairs, the interval between the foaming roller and the roll pair or the interval between the roll pairs is changed continuously or stepwise and in the same direction by the rotation driving means. The roll pair that is rotationally driven, It is characterized by crushing by pressing a foaming roller.

  In addition, the present invention that has achieved the above object is to set a core material and a foaming roller having a cylindrical foam layer formed on the outer periphery of the core material. Polyurethane raw material for forming the body layer is injected, this is heated and cured to form, and the formed foaming roller is foamed by the crushing method of the present invention or using the crushing apparatus of the present invention. It is a manufacturing method of a roller.

  The present invention has the following effects.

  (1) According to the crushing method of the present invention, good crushing can be performed on the foam layer of the cylindrical foam roller even with only one roll pair. As a result, the equipment can be reduced in size.

  (2) According to the method for producing a foaming roller of the present invention, preferably by changing the distance between the roll pair when pressing the foaming roller or the distance between the foaming roller and the roll pair continuously or stepwise. By controlling numerically, it is possible to obtain a suitable foaming roller without cracking during crushing for various foaming rollers.

  (3) Since the crushing device of the present invention is small, it can be easily handled and can be easily installed at a desired location.

  The present invention is described in more detail below. First, a crushing apparatus and a crushing method according to the present invention will be described with reference to the drawings.

  A side (schematic) view of the crushing apparatus of the present invention is shown in FIG.

The foaming roller crushing apparatus of the present invention has a pair of rolls arranged in parallel, means for rotationally driving the pair of rolls in the same direction, and means for varying (opening and closing) the interval between the pair of rolls. It comprises a crushing portion, a clamping portion having means for rotatably fixing both ends of the core material of the foaming roller, and means for transferring this between the pair of rolls.

  In the pair of rolls in the crushing section, the rolls 20 and 21 are arranged in parallel. The arrangement of the roll pair is not limited to the top and bottom, but may be arranged left and right or diagonally.

  The rotation of the roll pair preferably rotates the pair of rolls 20 and 21 synchronously. As a means for rotationally driving the roll pair in the same direction, each roll 20, What rotates 21 in the same direction and the same speed is preferable.

  As means for changing (opening and closing) the interval between the roll pairs, it is preferable to employ a numerical control device to precisely control the opening / closing speed and roll interval of the roll pairs. As a configuration, for example, a ball screw 24 having different threading directions at the left and right ends is used, and rolls 20 and 21 are disposed at both ends of the ball screw to form a pair. The drive motor 25 is preferably a servo motor or a stepping motor capable of precise position control.

  The material of the rolls 20 and 21 is preferably SUJ2 (bearing steel), but is not limited to this, and uses general steel materials, stainless steel materials, aluminum alloy materials, resin-based materials, and the like. Also good.

  There is no restriction | limiting in particular about the surface of the rolls 20 and 21, The thing which carried out mirror surface processing, the thing which roughened, the thing which gave the unevenness | corrugation, etc. can be used.

  Next, the clamp part will be described. The clamp part is composed of a fixing mechanism part that is a means for rotatably fixing both ends of the core material of the foam roller, and a transfer mechanism part that is a means for transporting the clamped foam roller to the crushing part.

  The fixing mechanism can be configured to have a reverse center bearing 26 and an air cylinder 27, but there is no particular limitation as long as it is a mechanism that can rotate around the axis of the core during clamping, and a cam follower receiver or the like is also used. be able to.

  The transfer mechanism unit can be constituted by an air cylinder 28. In this case, the fixing mechanism is pushed by the air cylinder 28 and transferred. Of course, it is also possible to use a configuration in which the transfer speed and transfer position are precisely controlled using a ball screw or the like.

  Next, the crushing method for the foaming roller of the present invention will be described.

The foaming roller crushing method of the present invention is a method of crushing a foaming roller having a core material and a cylindrical foam layer formed on the outer periphery of the core material, and arranged in parallel to rotate in the same direction. A foaming roller that performs crushing treatment is disposed between the pair of rolls that is parallel to the roll pair, and the spacing between the foaming roller that performs crushing treatment and the roll pair or the spacing between the roll pairs. The method is characterized in that the crushing is performed by pressing with a pair of rolls while continuously changing in a stepwise manner.

  In the crushing method of the present invention, the above-described crushing apparatus of the present invention can be used. In an example of the embodiment of the present invention, the crushing apparatus shown in FIG. 5 is used. First, the foaming roller to be subjected to the crushing process is set on the foaming roller receiver 29 of the fixing mechanism, and the bearing 26 of the reverse center receiver is set. Is pressed by the air cylinder 27, the both ends of the core material 2 are clamped and the foaming roller is rotatably fixed, the clamped foaming roller is pushed together with the fixing mechanism part by the air cylinder 28, and the roll 20 and the roll 21 of the crushing part are pressed. Move between pairs. Next, the roll pairs 20 and 21 are rotated in the same direction and at the same speed via the pulley 23, and the ball screw 24 is rotated by driving the servo motor which is the drive motor 25, and the gap between the roll pairs is closed. As shown, the foaming roller is pressed and the crushing process is performed while the foaming roller is driven to rotate. After an arbitrary time has elapsed, the roll pair is opened and the crushing process is completed.

  The timing for opening and closing the roll pair, the speed, the roll pair interval, or the interval between the foam roller and the roll pair can be arbitrarily changed by numerical control, and can be processed under crushing conditions suitable for various foam rollers.

  Next, the manufacturing method of the foaming roller of this invention is demonstrated. The foaming roller manufacturing method of the present invention is manufactured by first forming a foaming roller having a core material and a cylindrical foam layer formed on the outer periphery of the core material, and then crushing it. To do.

  The foaming roller that performs the crushing treatment is a cylindrical foam on the outer periphery of the core material by setting a core material in the mold, injecting polyurethane raw material to form a foam layer into the mold, and heating and curing it. Form and mold layers. The molded foam roller is subjected to a crushing treatment by the above-described crushing method of the present invention or by using the above-described crushing apparatus of the present invention.

  The foaming roller to which the crushing treatment in the present invention is applied can be formed by, for example, the following method.

  Polyols and polyisocyanates that are components of thermosetting liquid polyurethane rubber, which is a polyurethane raw material that forms the foam layer, catalysts, and foam stabilizers, foaming agents, crosslinking agents, and other auxiliaries, if desired. A thermosetting liquid polyurethane rubber, which is a polyurethane raw material, is prepared by mixing and stirring uniformly. The prepared thermosetting liquid polyurethane rubber is discharged to a liquid receiver 18 heated to a predetermined temperature (50 ° C. to 90 ° C.) as shown in FIG. Is assembled to a cylindrical pipe mold 17 (50 ° C to 90 ° C). The thermosetting liquid polyurethane rubber fills the pipe mold 17 by natural foaming. The filled thermosetting liquid polyurethane rubber is cured by heating at a temperature of 50 to 90 ° C. for 1 to 20 minutes to form a cylindrical foam layer on the outer periphery of the core 16, and from the cylindrical pipe mold 17. Demold and mold.

  For example, the foaming roller of the present invention is produced by crushing the foaming roller formed by the above-described method by the above-described crushing method of the present invention or the above-described crushing apparatus of the present invention. Is to be manufactured.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

(Example 1 and Comparative Example 1)
A foaming roller having the shape shown in FIG. 1 was molded as follows.

  Polyether polyol, FA-908 (manufactured by Sanyo Chemical Industries, Ltd .; trade name, OH value = 24), 90 parts by mass, polymer polyol, POP-31-28 (manufactured by Mitsui Takeda Chemical Co., Ltd .; trade name, OH value = 28) ) 10 parts by mass, tertiary amine catalyst, TOYOCAT-ET (manufactured by Tosoh Corporation; trade name) 0.1 part by mass, tertiary amine catalyst, TOYOCAT-MR (manufactured by Tosoh Corporation; trade name) 0.3 Mass parts, 2 parts by mass of water (foaming agent), silicone foam stabilizer, 1 part by mass of L5366 (manufactured by Nihon Unicar Co., Ltd .; trade name) are mixed in advance to obtain a mixed polyol, and these are mixed with isocyanate and coronate 1025 (Japan polyurethane). Kogyo Co., Ltd .; trade name, NCO = 40%) 22 parts by mass are mixed and stirred to prepare a thermosetting liquid polyurethane rubber that is a polyurethane raw material. It was. Apply silicone oil mold release agent to cylindrical pipe mold (hereinafter referred to as mold), set cylindrical metal core (φ5, length 260mm) in mold and heat to 60 ° C, then polyurethane The raw material was discharged into a liquid receiver, the liquid receiver and the mold were assembled, and the polyurethane raw material was filled into the mold by natural foaming. Then, it is heated and cured in a hot plate controlled at 60 ° C. for 10 minutes to form a cylindrical foam layer on the outer periphery of the core material, which is removed from the mold and subjected to a crushing process ( (Sometimes referred to as an uncrushed foaming roller). The non-crushing foaming roller was used as the foaming roller of Comparative Example 1.

  The obtained uncrushing-treated foaming roller was subjected to a crushing treatment using a crushing apparatus shown in FIG. 5 to make the foam cells communicated to obtain a foaming roller of this example.

  The crushing conditions were as follows.

  The non-crushing foaming roller to be crushed is a foam made of the core material (φ5, length 260mm) and the foam layer (outside diameter φ12-16, length 219mm). Crushing was carried out with the amount of crushing of the layer being 70% of the layer thickness of the foam layer, crushing time of 5 s, crushing device rotation speed constant at 400 rpm, and roll opening / closing speed of 0.5 to 1.0 mm / s.

(Evaluation of foam roller)
The foaming roller of the example or the comparative example was evaluated based on observation of defects such as cracks on the surface of the foam layer by visual observation and measurement of the next air flow rate. The obtained results are shown in Table 1.

(1) Measurement of air flow The air flow of the foaming roller of the example or the comparative example was measured by supplying air in the longitudinal direction of the foaming roller using the air flow measuring device AP-500KZ (trade name) manufactured by Daiei Kagaku Seiki Seisakusho. Measured.

  As shown in Table 1, the foaming roller of Example 1 had a ventilation rate increased by 25% compared with the foaming roller of Comparative Example 1, and good communication was confirmed. Moreover, the foaming roller of Example 1 showed no defects such as cracks on the foam surface.

  INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a crushing method and apparatus that realizes good crushing of a foaming roller and realizes downsizing of equipment, and a method of manufacturing a foaming roller using these.

It is the schematic of the foaming roller in this invention. It is a schematic diagram which shows the cross section at the time of the crushing process of the foaming roller in this invention. It is a schematic diagram which shows the cross section at the time of the crushing process of the foaming molding by the crushing apparatus of the conventional method. It is a schematic diagram which shows an example of the liquid receptacle used for shaping | molding of the foaming roller in this invention, and a cylindrical pipe metal mold | die. It is a side (schematic) figure of the crushing apparatus of this invention.

Explanation of symbols

1: Foam layer 2: Core material 10: Foam molded body 11: Roll 15: Upper piece 16: Core material 17: Pipe mold 18: Liquid receiver 20: Roll 21: Roll 22: Drive motor shaft 23: Pulley 24 : Ball screw 25: Drive motor 26: Bearing 27: Air cylinder 28: Air cylinder 29: Foam roller receiver 30: Pulley belt

Claims (4)

In a foaming roller crushing method having a core material and a cylindrical foam layer formed on the outer periphery of the core material, the foaming is performed between a pair of rolls arranged in parallel and rotating in the same direction. the rollers are arranged parallel to said roll pair, the distance interval or the roll pairs in the foam roller and said roll pair, continuously or stepwise changed, the roll of a pair of foamed roller A crushing method for a foaming roller, characterized by pressing in pairs. A core material, the crushing apparatus of the foam roller having a cylindrical foam layer formed on the outer periphery of the core member, a pair of roll pairs arranged in parallel, rotationally driving the roll pairs in the same direction Means for varying the spacing between the roll pairs, means for rotatably fixing both ends of the core of the foam roller, and means for transporting the foam roller between the roll pairs, Means for fixing the both ends of the core material of the foam roller in a rotatable manner by means for fixing, and arranging it in parallel to the pair of rolls by means for transferring, and means for varying the interval between the pair of rolls; The foam roller is pressed with the roll pair that is rotationally driven in the same direction by the rotation driving means by changing the interval between the foam roller and the roll pair or the interval between the roll pair continuously or stepwise. It is characterized by classifying Crushing device.   3. The crushing apparatus according to claim 2, wherein the means for changing the interval between the roll pairs uses a drive motor controlled by a numerical controller.   A core material and a foaming roller having a cylindrical foam layer formed on the outer periphery of the core material, a core material is set in a mold, and a polyurethane raw material that forms the foam layer is injected into the mold, A method for producing a foaming roller, wherein the foaming roller is heat-cured and molded, and the molded foaming roller is crushed by the crushing method according to claim 1 or by using the crushing apparatus according to claim 2 or 3.

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