JP5009584B2 - Cushion material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a cushion material housed in a bedding such as a futon or a pillow or a cushion.

  The cocoon has the feature that it has excellent heat retention and is not easily charged with static electricity. In addition, soot has the property of absorbing moisture and releasing moisture, and has excellent hygroscopicity and moisture releasing properties. Therefore, by using rice husk as a cushioning material such as bedding, night sweat and the like can be effectively absorbed and dried. In addition, since rice husks are difficult to carry static electricity, it is possible to prevent static discomfort in winter.

  Then, the futon etc. which used chaff as a cushioning material like patent document 1 and patent document 2 are proposed. The idea described in Patent Document 1 is a futon containing a cocoon layer in which a rice husk or a barbarian husk is used as a stuffing and sewn with a cloth. The invention described in Patent Document 2 is a cushion material that is built in a cover body such as a futon, and the cushion material is composed of a plurality of ridges filled with an elastic material.

In the above-mentioned, the original rice husk is used as it is without being processed, and a relatively hard oval (shell-shaped) rice husk is filled as a cushioning material. Due to the oval shape (convex shape) peculiar to the rice husk, every time a person who sleeps in a futon turns over, the hard husk sensation of the rice husk is accompanied by discomfort, and sometimes he cannot wake up and sleep well. Furthermore, when the body is turned sideways while sleeping (when weight is applied to one side), the rice husk is oval (spherical) and unstable, so many rice husks move to the other side of the futon. Can't sleep comfortably. Even when the cushions and cushions are filled, the rice husks move from the parts where the weight is applied (such as the buttocks) and lack comfort. In addition, when used as a pillow, noise is generated due to movement of rice husks, giving unpleasant feeling.
No. 6-4761 Japanese Patent No. 2599401

  Therefore, the problem to be solved by the present invention is to provide a cushioning material capable of reducing the problems caused by the original shape of the above-described rice husk while having features such as moisture absorption / release properties and heat retaining properties of the cocoon, and a method for manufacturing the same. There is.

The cushion material according to the present invention is a cushion material housed inside a futon, a pillow, etc., and a plurality of substantially elliptical rice husks have a predetermined thickness, and both sides facing each other are flat or The upper side and the lower side are crushed in the longitudinal direction, and a plurality of rice husks are coated with a hydrolyzed silk solution and are held in shape.

The method for producing a cushion material according to the present invention is a method for producing a cushion material housed inside a futon, a pillow, etc., and applying a hydrolyzed silk solution to a plurality of substantially oval rice husks, A plurality of rice husks are sent to a pair of rotating rollers arranged at a distance narrower than the thickness of the rice husk, and both sides facing each other are flattened with a predetermined thickness between the rotating rollers. Or it crushes so that it may become depressed , and the upper side and the lower side are crushed in the longitudinal direction .

  As described above, the cushion material according to the present invention is formed by crushing a plurality of substantially oval rice husks in a state having a predetermined thickness so that both sides facing each other are flat or hollow. The rice husk has a characteristic that the inside is hollow and a large amount of air is present, so that heat retention is excellent. Accordingly, in the present invention, the rice husk is crushed into a state having a predetermined thickness (a state in which a cavity remains inside), thereby providing an air layer to ensure heat retention and elasticity as a cushioning material. Can be held.

  Furthermore, by disintegrating the rice husk so that both sides facing each other are flattened or depressed, discomfort due to the original shape (elliptical shape) of the rice husk can be reduced. In other words, there is no strong irritation due to the unevenness of the rice husks, so you can sleep well and never wake up. In addition, the rice husk is stable and the rice husk does not move much even if it is turned over, and when it is filled in a cushion, it can give a sense of stability to the user who sits on it, and can also be used as a pillow. There is an excellent effect of eliminating the noise at the time.

  The extent to which the rice husks are crushed depends on the shape and size of the rice husk, the purpose of use, etc. It can be changed and determined accordingly.

  The rice husk is coated with hydrolyzed silk liquid in order to maintain its shape. The hydrolyzed silk liquid is a liquid obtained by hydrolyzing and extracting silk fibers, and is a solution composed of sericin (amino acid) and silk fibroin. Since the hydrolyzed silk liquid has viscosity, by applying this hydrolyzed silk liquid to rice husks, it is possible to maintain the shape while ensuring the characteristics of the rice husks, reducing deformation due to use, Works well as a padding for cushions and cushions.

  In addition, the rice husk has an elliptical original shape and a long upper and lower sides, so that the upper and lower sides are easily crushed in the longitudinal direction, and is excellent in workability and productivity.

  Furthermore, as described above, according to the method for manufacturing a cushion material according to the present invention, the hydrolyzed silk liquid is applied to a plurality of rice husks and then crushed by a pair of rotating rollers. Thus, by applying the hydrolyzed silk solution before crushing, the crust is crushed with a predetermined strength, so that the shape of the crushed chaff can be made uniform. In addition, by using a rotating roller, a large amount of rice husk can be crushed in a short time, which is excellent in productivity and cost.

  Further, by changing the gap between the pair of rotating rollers, the shape of the cushion material (crushed rice husk) can be changed relatively easily in accordance with the original shape of the rice husk and the purpose of use.

  Hereinafter, a cushioning material and a manufacturing method thereof according to the present invention will be described in detail based on the drawings.

  FIG. 1 is an overall view for explaining a cushion material and a manufacturing method thereof according to the present invention, (a) is a perspective view showing an original chaff, (b) is a perspective view showing a pressing device, (c) ) Is a side view showing a crushed chaff (cushion material). FIG. 2 is a sectional side view showing the pressing device. In each figure, reference numeral 1 denotes a rice husk that is partially cut open to form an opening 1a, and the inner pupa is taken out from the opening 1a. 3 is a pressing device for crushing the chaff 1. The pressing device 3 includes a main body 33. A hopper 30 is connected to the upper portion of the main body 33.

  The pressing device 3 includes a first roller 4 and a second roller 5 inside the main body 33. The first and second rollers 4 and 5 are extended in the width direction of the pressing device 3 (the depth direction in FIG. 2). The first roller 4 and the second roller 5 are arranged in parallel at a predetermined interval L. Each of the rollers 4 and 5 is configured to be rotationally driven by a drive motor 6 (FIG. 3) described later. The drive motor 6 is connected to a switch 31 provided in the main body 33, and is started and stopped by turning on / off the switch 31. A discharge plate 32 is provided below each of the rollers 4 and 5. The discharge plate 32 is inclined downward.

  Next, the manufacturing method of the cushion material of this invention is demonstrated. First, the switch 31 provided in the pressing device 3 is turned on to start the drive motor 6. Thereby, each roller 4 and 5 rotates. Then, a plurality of rice husks 1 are charged into the charging port 30 a at the upper end of the hopper 30. The rice husk 1 is obtained by spraying a predetermined amount of hydrolyzed silk liquid in advance. Since this hydrolyzed silk liquid has viscosity and is obtained by hydrolyzing silk fibers, the shape of the rice husk 1 can be maintained without impairing the original characteristics of the rice husk. Thereby, while being able to arrange the shape of cushion material (crushed rice hulls) 2, restoration to the original form by elasticity can be prevented.

  As shown in FIG. 2, a guide port 30 b is provided on the upper side of the main body 33. The guide port 30b is located immediately above the interval between the rollers 4 and 5. Accordingly, the plurality of rice husks 1 thrown into the hopper 30 are guided to the guide port 30 b and guided between the rollers 4 and 5. The distance L between the rollers 4 and 5 is smaller than the diameter of the chaff 1. Furthermore, each roller 4 and 5 is rotating from the upper part to the lower part in the proximity | contact part (refer the arrow of FIG. 2). Therefore, the rice husk 1 guided between the rollers 4 and 5 is crushed and dropped downward. Since the original chaff 1 is oval (saddle-shaped), the upper and lower sides in the longitudinal direction of the chaff 1 guided between the rollers 4 and 5 are naturally crushed by the rollers 4 and 5. The crushed rice husk 2 is dropped and guided to the discharge plate 32 and discharged from the pressing device 3.

  As shown in FIG. 1C, the cushion material (crushed rice husk) 2 has a flat or hollow upper side 2a and lower side 2b with the longitudinal direction as the front-rear direction. The height H is determined according to the distance L between the rollers 4 and 5. As will be described later, the distance L between the rollers 4 and 5 is the height of the cushion material (crushed rice husk) 2 according to the original shape and size of the rice husk 1 or the use mode of the cushion material 2 and the like. It can be changed so that H (thickness) can be adjusted. In addition, in order to ensure the heat retaining property as the cushion material 2, the chaff 1 is not completely crushed (in a state where the rollers 4 and 5 are in contact with each other). The height H is preferably about 1/3 to 2/3 of the height of the original rice husk 1.

  By the above-described method, a large number of cushion materials (crushed rice husks) 2 are manufactured and filled into a futon, a pillow cover, and a cushion cover to produce a futon using the cushion material 2 according to the present invention. The cushion material 2 filled in the futon or the like is produced from the rice husk 1, and thus has the effect of being excellent in moisture absorption and moisture release and being hardly charged with static electricity. Furthermore, by ensuring the height H of the rice husk 2, air can be present in the interior, excellent in heat retaining properties, and further can retain elasticity as a cushioning material. Moreover, since the upper and lower sides of the cushion material 2 are flat or depressed, it is stable and hardly moves.

  Next, the pressing device 3 will be described in detail. FIG. 3 is a right side view showing a part of the pressing device. FIG. 4 is a left side view showing a part of the pressing device. FIG. 5 is a cross-sectional view taken along line I-I shown in FIG. In FIG. 3, the cover 34 and the switch 31 provided on the right side of the main body 33 shown in FIG. 1 are omitted for easy understanding.

  As shown in FIGS. 3 and 5, the pressing device 3 includes a first gear 40 and a second gear 50 on the right side of the main body 33. The gears 40 and 50 are fitted and meshed with each other. The first gear 40 is connected to the right side of the first shaft 46 in the first roller 4. The second gear 50 is connected to the right side of the second shaft 56 in the second roller 5. Further, the first gear 41 is connected to the first pulley 41. A second pulley 42 is provided below the first pulley 41. An endless belt 43 is bridged between the pulleys 41 and 42.

  The second pulley 42 is configured to be rotationally driven by a drive motor 6 (dotted line) provided inside the main body. As described above, the drive motor 6 is connected to the switch 31, and starts / stops by turning the switch 31 ON / OFF. By driving the drive motor 6, the second pulley 42 rotates and the first pulley 41 rotates via the endless belt 43. The first gear 41 is rotated by the rotation of the first pulley 41, and the second gear 50 is rotated following the rotation. The rotation of the gears 40 and 50 causes the rollers 4 and 5 to rotate in reverse relative to each other and drop from the upper side to the lower side while crushing the rice husk 1 as described above.

  As shown in FIGS. 4 and 5, the pressing device 3 includes first bearings 45 and 45 and second bearings 55 and 55 on the left and right sides of the main body 33. The first bearings 45 and 45 support the first shaft 46 of the first roller 4, and the second bearing 55 supports the second shaft 56 of the second roller 5. Further, each of the second bearings 55 and 55 includes second roller moving means 7 and 7, respectively. The moving means 7 is configured to move the second roller 5 in a direction perpendicular to the axial direction thereof. Has been. By moving the second roller 5, the distance L between the rollers 4 and 5 can be changed according to the original rice husk 1 or the like.

  The second roller moving means 7 includes a bolt 71 connected to the second bearing 55. The bolt 71 extends in the moving direction (a direction perpendicular to the axial direction of the second roller 5). The bolt 71 is screwed into a restriction plate 72 fixed to the main body 33. A nut 73 is provided at a portion of the bolt 71 protruding from the restriction plate 72. Furthermore, guide plates 74 and 74 fixed to the main body 33 and extending in the moving direction are provided above and below the second bearing 55.

  And by rotating the nut 73 forward and backward, the second bearing 55 can be moved forward and backward together with the bolt 71. At that time, the movement of the second bearing 55 in the vertical direction is regulated by the guide plates 74 and 74 and moves smoothly in the movement direction. Accordingly, by moving the second bearing 55, the second roller 5 moves. Further, a compression spring 70 is wrapped around the bolt 71. The compression spring 70 is provided between an annular projecting piece 71a fixed to the bolt 71 and the second bearing 55, and presses and urges 71a and 55, respectively. Due to the action of the compression spring 70, the second bearing 55 and the second roller 5 are positioned and urged.

  As shown in FIG. 5, the first roller 4 includes a plurality of grooves 4a. The groove portion 4 a is composed of two grooves inclined in different directions with respect to the axial direction, and intersects at the center of the roller 4. The second roller 5 includes a plurality of grooves 5a, and the grooves 5a extend in the axial direction. In each roller 4, 5, the arrangement of the grooves 4 a, 5 a of 4, 5 is configured as described above, so that the rice husk 1 falls smoothly without clogging and a cushion material (crushed rice husk) ) The shape of 2 can be adjusted.

  In addition to crushing with the above-described pressing device, it may be crushed with a plate from above and below with a pressing device or an iron. In addition to flattening or hollowing the upper and lower sides of the rice husk in the longitudinal direction, it may be flattened or hollowed in the longitudinal direction of the longitudinal direction. In addition, it is preferable to apply the hydrolyzed silk liquid to the chaff before crushing, but the hydrolyzed silk liquid can also be applied to the chaff after crushing to maintain the shape.

BRIEF DESCRIPTION OF THE DRAWINGS It is a general view for demonstrating the cushioning material which concerns on this invention, and its manufacturing method, (a) is a perspective view which shows an original chaff, (b) is a perspective view which shows a pressing device, (c) is crushed It is a side view which shows the rice husk (cushion material). It is a cross-sectional side view which shows a pressing device. It is a right view which shows a part of press apparatus. It is a left view which shows a part of press apparatus. It is the II sectional view taken on the line shown in FIG.

Explanation of symbols

1 Original rice husk 2 Cushion material (crushed rice husk)
2a Upper side of cushion material 2b Lower side of cushion material H Height (thickness) of cushion material
3 Pressing device 4 First roller 5 Second roller L Distance 7 between first roller and second roller 7 Second roller moving means

Claims (2)

A cushion material housed inside a futon, pillow, etc., in a state where a plurality of substantially oval rice husks have a predetermined thickness, both sides facing each other are crushed flat or hollow , and The upper and lower sides are crushed in the longitudinal direction,
The plurality of rice husks are coated with a hydrolyzed silk solution and are held in shape . A method of manufacturing a cushion material stored inside a futon or pillow,
A hydrolyzed silk solution is applied to a plurality of substantially elliptical rice husks, and then the plurality of rice husks are sent to a pair of rotating rollers arranged at a distance narrower than the thickness of the rice husks. Cushioning material characterized in that it is crushed between rotating rollers with a predetermined thickness so that both sides facing each other are flattened or depressed , and the upper and lower sides are crushed in the longitudinal direction. Method.

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