JP5378617B2 - Three-dimensional network structure, three-dimensional network structure manufacturing method, and three-dimensional network structure manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and apparatus for producing a three-dimensional network structure, which eliminates the need for finishing in a post-process, enhances a degree of arrangement, can respond to an irregular shape, and has improved durability. <P>SOLUTION: There is provided a plate-like three-dimensional network structure 1 composed of a thermoplastic resin as a raw material or a main raw material, in which a plurality of wires are helically and randomly entangled and partially heat-bonded. It is preferable that the density on any surface side of at least three or four surfaces of the outer periphery of the three-dimensional network structure is relatively lower than that of a portion except the surface side. A flaky or chip-like material of a PET bottle is used as the raw material or the main raw material of the thermoplastic resin, which is obtained by directly pulverizing the PET bottle to melt them into a flaky shape, and is adapted to a recycling promotion age, and works well in cost reduction of waste disposal. Main applications of the three-dimensional network structure 1 include a shock-absorbing material, a cushioning material, a sound-absorbing building material, and the like. <P>COPYRIGHT: (C)2013,JPO&amp;INPIT

Description

  The present invention relates to a three-dimensional network structure, a three-dimensional network structure manufacturing method, and a three-dimensional network structure manufacturing apparatus used for a cushion material or the like.

  Conventionally, as a method for producing a three-dimensional network structure having voids, a method described in Japanese Patent Publication No. 50-39185, or a resin cotton obtained by bonding polyester fibers with an adhesive, for example, a rubber-based adhesive is used. -11352 etc. are known. On the other hand, there is a method or a manufacturing apparatus for manufacturing a three-dimensional network structure having voids by winding resin yarn with an endless belt, and the invention shown in Japanese Patent Application Laid-Open No. 11-241264 is cited.

Japanese Patent Publication No. 50-39185 JP 60-11352 A JP-A-11-241264

However, the demand for such three-dimensional network structure products is diversified, and it is necessary to cut or mold into the required shape in the subsequent process of the manufacturing process to finish the irregular network body one by one. It gets complicated.
In addition, a three-dimensional network structure manufactured by a conventional method may have a low density, and since both surfaces of the bundle are in contact with the belt conveyor, the surface is substantially flattened. Is a random spiral shape, and the sides are misaligned to wave in the lateral direction.
On the other hand, although it is wound with an endless belt, the endless belt is easily damaged by heat or the like, which may cause a problem in durability.
Accordingly, the present invention provides a manufacturing method and a manufacturing apparatus for a three-dimensional network structure that eliminates the need for finishing in a subsequent process, increases the degree of alignment, makes it possible to cope with irregular shapes, and improves durability. Objective.

The three-dimensional network-structure manufacturing apparatus according to claim 1, wherein a molten filament made of a thermoplastic resin as a raw material or a main raw material is extruded downward from a die having a plurality of holes, and is naturally lowered between submersed drawing devices, The wire is drawn slower than the descending speed, the interval of the drawing device is set narrower than the width of the extruded wire assembly, and at least three or four surfaces of the wire assembly are drawn into the drawing device. It is arrange | positioned so that it may contact. This eliminates the need for finishing in the subsequent process and increases the degree of alignment.
In the method for producing a three-dimensional network structure according to claim 2, a molten filament made of a thermoplastic resin as a raw material or a main raw material is extruded downward from a die having a plurality of holes, and is naturally lowered between submerged drawing devices, The wire is drawn slower than the descending speed, the interval of the drawing device is set narrower than the width of the extruded wire assembly, and at least three or four surfaces of the wire assembly are in contact with the drawing device It is. This eliminates the need for finishing in the subsequent process and increases the degree of alignment.

According to the first and second aspects of the present invention, there is provided a method and an apparatus for manufacturing a three-dimensional network structure that eliminates the need for finishing in the subsequent process, increases the degree of alignment, makes it possible to cope with irregular shapes, and improves durability. The industrial utility value that can be provided and given to various industries is extremely large.

FIG. 1 is a perspective view of a three-dimensional network structure according to the first embodiment of the present invention. 2A is a longitudinal sectional view of the three-dimensional network structure according to the first embodiment of the present invention, FIG. 2B is a longitudinal sectional view of the three-dimensional network structure according to the second embodiment, and FIG. 2C is a fourth embodiment. (D) is a longitudinal sectional view of the three-dimensional network structure of the fifth embodiment, (e) is a longitudinal sectional view of the three-dimensional network structure of the sixth embodiment, ( f) is a longitudinal sectional view of the three-dimensional network structure of the seventh embodiment, and (g) is a longitudinal sectional view of the three-dimensional network structure of the eighth embodiment. FIG. 3A is a longitudinal sectional view of the three-dimensional network structure according to the ninth embodiment, and FIG. 3B is a side view of the three-dimensional network structure according to the ninth embodiment. 4A to 4G are cross-sectional views of the three-dimensional network structure according to the third embodiment. FIG. 5 is a perspective view of the three-dimensional network structure manufacturing apparatus according to the first embodiment. FIG. 6 is an explanatory diagram illustrating an operation state of the three-dimensional network structure manufacturing apparatus according to the first embodiment. 7A and 7B are a side view and a front view of an endless conveyor of the three-dimensional network structure manufacturing apparatus. FIGS. 8A to 8F are side views of the same three-dimensional network structure manufacturing apparatus and a modified endless conveyor. FIG. 9A is a plan view of an endless conveyor of a three-dimensional network structure manufacturing apparatus in the case of four-side molding, FIG. 9B is a side view of the three-dimensional network structure manufacturing apparatus, and FIG. Side view of four-sided three-dimensional network structure manufacturing apparatus, (d) is a plan view showing a four-sided molding by the three-dimensional network structure manufacturing apparatus, and (e) is a three-side molding by the three-dimensional network structure manufacturing apparatus. It is a top view which shows the mode of. 10A is a plan view of an endless conveyor of a three-dimensional network structure manufacturing apparatus having an independent drive structure in the case of four-side molding, and FIGS. 10B and 10C are three-dimensional network structure manufacturing apparatuses provided with sliding plates on the end faces. It is an endless conveyor. FIGS. 11A to 11H are a plan view and a front view showing various forms of a die base. 12 (a) and 12 (b) are front views of an endless conveyor of a three-dimensional network structure manufacturing apparatus for four-sided molding in a modified form. FIG. 13A is a longitudinal sectional view of the three-dimensional network structure of the tenth embodiment, FIG. 13B is a longitudinal sectional view of the three-dimensional network structure of the eleventh embodiment, and FIG. 13C is a three-dimensional network structure of the twelfth embodiment. (D) is a longitudinal cross-sectional view of the three-dimensional network structure of 13th Embodiment. 14A is a longitudinal sectional view of the three-dimensional network structure according to the fourteenth embodiment, FIG. 14B is a longitudinal sectional view of the three-dimensional network structure according to the fifteenth embodiment, and FIG. 14C is a three-dimensional network structure according to the sixteenth embodiment. It is a longitudinal cross-sectional view of a body. FIG. 15 is a perspective view of the three-dimensional network structure manufacturing apparatus according to the second embodiment. FIG. 16A is a cross-sectional view of the vicinity of the upper portion of the die of the composite die of the three-dimensional network structure manufacturing apparatus according to the embodiment of the present invention, and FIG. 16B is a front view of the lower portion of the composite die. FIGS. 17A and 17B are explanatory views of a modified form of the three-dimensional network structure manufacturing apparatus according to the second embodiment. 18 (a), (b), and (d) are plan views showing various forms of a die base, and (c) is a front view of (d). 19A to 19D are plan views showing various forms of a die base. FIG. 20 is an explanatory diagram showing an operation state of the three-dimensional network structure manufacturing apparatus according to the third embodiment. 21A and 21B are a side view and a front view of a roll of the three-dimensional network structure manufacturing apparatus. 22 (a) to 22 (g) are side views of the same three-dimensional network structure manufacturing apparatus and modified rolls. FIG. 23A is a front view of a three-dimensional network structure (applied to a horticultural cushioning material or the like) of the seventeenth embodiment, FIG. 23B is a plan view of the three-dimensional network structure, and FIG. 23C is the three-dimensional network structure. (D) is a modified three-dimensional network structure. 24A is a plan view of a die base of the three-dimensional network structure manufacturing apparatus according to the fourth embodiment, FIG. 24B is a front view thereof, FIG. 24C is a plan view of a die base of another die, and FIG. It is the same front view. FIG. 25 is an explanatory view showing a usage state of the three-dimensional network structure according to the seventeenth embodiment. FIG. 26 is an explanatory view showing another usage state of the three-dimensional network structure according to the seventeenth embodiment. FIG. 27 is a partial structural view of the three-dimensional network structure manufacturing apparatus according to the fourth embodiment.

  Hereinafter, as shown in FIG. 1 and FIG. 2A, the three-dimensional network structure 1 according to the first embodiment uses a regenerated thermoplastic resin as a raw material or a main raw material, and a plurality of filaments are randomly entangled in a spiral manner. A three-dimensional network structure characterized in that it is a plate-shaped three-dimensional network structure that is thermally bonded to each other, and has two side surfaces, left and right end surfaces, and upper and lower end surfaces. Of the side surfaces of the three-dimensional network structure, it is preferable that the density on the surface side of three surfaces is relatively higher than the density of the portion excluding the surface side. That is, the three-dimensional network structure 1 (see FIG. 2A) of the first embodiment is a three-sided molding, and a region at a predetermined interval is formed with a high density from the opposite one side toward the inside. The density of the region inside the central portion is set lower than that, and the other surface is uneven. For this reason, the advantage which does not process in a post process arises. That is, a pair of wide surfaces and one side surface are forcibly formed by an endless conveyor or the like, which will be described later, and the edges are aligned more cleanly than the other surfaces.

Here, a flake shape or a chip shape of a PET bottle is used as a raw material or main raw material of the recycled thermoplastic resin. A PET bottle is crushed as it is and melted to form a flake. It is also suitable for the era of recycling promotion. If this is not a recycled product but a genuine product, the production cost per 1 m ² will be doubled in terms of cost, such as dry crystallization or dust removal. Can be used to reduce waste disposal costs. However, it can also be applied to thermoplastic resins other than recycled materials. For example, as thermoplastic resins, polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides such as nylon 66, polyvinyl chloride, polystyrene, copolymers and elastomers based on the above resins, blends of the above resins, etc. Is mentioned. Furthermore, the applications of the three-dimensional network structure 1 are mainly cushion materials, impact absorbing materials, moisture absorbing materials, sound absorbing materials (under floor materials, inside, inside walls), heat insulating materials (internal and external heat insulation), wall surfaces Examples are applied to rooftop greening, concrete mortar crack prevention materials, automobile interior materials, etc., but can also be applied to the inside of double walls.
In addition, the flame retardant material is mixed into the three-dimensional network structure by adding a flame retardant paint to the three-dimensional network structure, such as sandwiching or attaching the three-dimensional network structure with a nonwoven fabric such as carbon fiber. Is more suitable as a building heat insulating material, a building sound absorbing material, or the like.
In the first embodiment, the inside is generally formed to have a uniform density. The apparent density is preferably 0.02 to 0.9 g / cm ³ (corresponding to a porosity of 36 to 98.4%), particularly preferably 0.05 to 0.15 g / cm ³ . The three-dimensional network structure 1 preferably has a width of 0.1 m to 2 m and a thickness of 5 mm to 200 mm, is endless in the length direction, and is cut into an appropriate length (for example, 900 mm). It is not limited to.

  The three-dimensional network structure 2 (see FIG. 2 (b)) of the second embodiment is a four-sided molding and all the surfaces are aligned, and is directed from the left and right side surfaces of the three-dimensional network structure 1 of the first embodiment to the inside. Thus, the regions of the predetermined interval are formed with a high density, and the density of the region inside the central part is set lower than that. That is, except for the upper surface and the bottom surface, the regions with predetermined intervals from all the surfaces are formed with high density.

  The surface of the three-dimensional network structure 3 according to the third embodiment has an irregular shape or a polyhedral shape. For example, 3A provided with a convex surface (see FIG. 4A), 3B provided with a concave surface (see FIG. 4B), 3C provided with a plurality of continuously formed uneven surfaces (FIG. 4). (See (c)), 3D having a plurality of sawtooth surfaces (see FIG. 4 (d)), 3E having a plurality of wavefronts (see FIG. 4 (e)), and having a curved corner (R) shape 3F (see Fig. 4 (f)), 3G (see Fig. 4 (g)) whose corners are cut to a predetermined angle (45 ° here), or an appropriate combination thereof, etc. Various types of products are required as products, and this can be accommodated. Moreover, it is thought that various uses arise by setting it as a complicated shape. In particular, various product requirements can be satisfied by forcibly forming three or four surfaces of a three-dimensional network structure as in the first and second embodiments described above. More generally, for a deformed shape required for a product, the required shape is cut or molded in a subsequent process to form a deformed network, but according to this embodiment, the shape required for the product is obtained. The product can be provided immediately without finishing the dimensions in the post-process, and the post-process can be eliminated.

The three-dimensional network structure 4 (see FIG. 2C) of the fourth embodiment includes one or a plurality of (here, two) hollow portions 4A and 4B, and is intended to further reduce costs. It is what.
The three-dimensional network structure 5 (see FIG. 2D) of the fifth embodiment is a plate-like reproduction veneer in the hollow portions 5A and 5B similar to the hollow portions 4A and 4B of the three-dimensional network structure 4 of the fourth embodiment. The recycled members 5C and 5D are made of the same or different materials such as plate-shaped recycled shredder dust, and are intended to improve sound absorption, heat insulation, cushioning properties and the like by the recycled plate material.
The three-dimensional network structure 6 (see FIG. 2 (e)) of the sixth embodiment has a density increased in the thickness direction inside the three-dimensional network structure 1 of the first embodiment, and partially or singularly. By forming the three beam-like high-density regions 6A, 6B, and 6C at predetermined intervals, the sound absorbing property, heat insulating property, cushioning property, and impact resistance are improved.
The three-dimensional network structure 7 (see FIG. 2 (f)) of the seventh embodiment has a single or a plurality of (here, one) high-density region 7A in which the density is increased in the width direction. By forming, the sound absorbing property, heat insulating property, cushioning property and impact resistance are enhanced.
The three-dimensional network structure 8 (see FIG. 2 (g)) of the eighth embodiment is a corrugated high-density region 8A in the seventh embodiment, and has improved sound absorption, heat insulation, cushioning, and impact resistance. Is.

The three-dimensional network structure 9 (see FIG. 3A) of the ninth embodiment is formed by forming a sheet 9A (a region without a void) at a predetermined position in the width direction inside the three-dimensional network structures 1 and 2. Sound absorption, heat insulation, cushioning and impact resistance are improved. A filament (resin yarn) is entangled around the sheet 9A. The sheet 9A may be provided with a full width as shown in the figure, or may be provided partially, for example, in the central portion.
The sheet 9A of the three-dimensional network structure 9 (see FIG. 3B) of the ninth embodiment is generally wave-shaped, and has improved sound absorption, heat insulation, cushioning, and impact resistance. . The reason why it can be formed into such a corrugated shape is that, as will be described later, the roll take-up speed is slower than the resin yarn descending speed. The wave interval, height, width, and the like of the sheet 9A vary depending on manufacturing conditions, and are not limited to those illustrated. When the interval between the waves of the sheet 9A is narrow, they may be bonded to each other. The ninth embodiment can be manufactured by using the slit (linear through groove) 75a of FIG.
In addition, although not shown in the drawings, the present invention can also be implemented for a cross-sectional shape having a triangular shape such as a triangular shape or a Y-shaped shape.

(3D network structure manufacturing equipment)
Next, the three-dimensional network-structure manufacturing apparatus 10 will be described.
As shown in FIG. 5, the three-dimensional network-structure manufacturing apparatus 10 is configured to drive an extruder 11, a pair of endless conveyors 14 and 15 (see FIG. 7) including endless members 12 and 13, and a drive that drives the endless members 12 and 13. It consists of a motor 16, a chain and gears, a transmission 17 that changes the moving speed of the endless members 12, 13, a water tank 18 that partially submerses the pair of endless conveyors 14, 15, a control device 19, and other instruments. ing.
The endless members 12 and 13 are made of a plurality of (here, two each) endless chains 12 a and 13 a (a plurality of endless chains 12 a) each having a predetermined gap 22 (refer to FIG. 8A). 7 (a) and 7 (b)) are connected with screws (not shown). Instead of this, as shown in FIG. 8B, a belt 23 such as a stainless mesh (metal mesh) without the gap 22 may be used. This mesh belt is a combination of a spiral and a rod (brute), and various types can be produced depending on the shape, wire diameter, and pitch of these two elements. Smooth movement, excellent for keeping the belt surface horizontal, excellent for high temperature use, and easy repair. Alternatively, as shown by the dotted line in FIG. 7, a stainless mesh belt 23 stretched around the outer periphery of the endless members 12 and 13 can be implemented, which is suitable when it is desired to prevent the formation of irregularities due to the gap 22. The plate 21 has a rectangular cross section, but has a convex shape 24 (see FIG. 8C), a concave shape 25 (see FIG. 8D), and a sawtooth shape 26 (see FIG. 8E). )), And various modified forms such as a continuously formed concave-convex shape 27 (see FIG. 8F) are conceivable.

  As shown in FIG. 7, the endless conveyor 14 includes a drive shaft 14b having a sprocket 14a around which the endless chain 12a is wound, and a driven shaft 14d having a sprocket 14c. The endless conveyor 15 is driven in synchronism with the endless conveyor 14, and is arranged vertically, a driven shaft 15b having a sprocket 15a around which the endless chain 13a is wound, and a driven shaft 15d having a sprocket 15c. It has.

  As shown in FIG. 5, the extrusion molding machine 11 includes a container 31, a raw material supply port 32 provided in the upper portion of the container 31, a die 33, a base 34 that can be detachably fixed to a lower end portion of the die 33, and the like. The temperature range inside the die of the extruder 11 can be set to 100 to 400 ° C., the extrusion amount can be set to 20 to 200 kg / hour, and the like. The pressure range of the die 33 is 0.2 to 25 MPa, for example, a discharge pressure of a 75 mm screw. When the thickness of the three-dimensional network structure exceeds 100 mm, it may be necessary to make the die pressure uniform by a pump or the like. Therefore, it is necessary to increase the pressure in the die by a gear pump or the like in order to discharge the filaments uniformly from the entire area inside the die. At this time, in order to form the shape of the three-dimensional mesh sheet, each surface of the endless conveyors 14 and 15 is structured to be freely movable, the shape of the die 34 of the die 33 (density or diameter of the holes H) and the endless conveyors 14 and 15. A product having a desired density and strength can be manufactured according to the conveyance speed, and various requirements of the product can be satisfied.

Here, the three-dimensional network-structure manufacturing apparatus 50 in the case of a four-face molding machine as shown in FIGS. 9A and 9B will be described. The three-dimensional network-structure manufacturing apparatus 50 has endless conveyors 54 and 55 having rotating shafts 54a and 55a corresponding to the endless conveyors 14 and 15 in the case of two-side molding shown in FIG. A pair of rolls 56 and 57 having rotatable rotation shafts 56a and 57a in which the rotation shafts and the rotation shafts are arranged orthogonal to each other are disposed at the longitudinal ends of the rollers. The rotating shaft 54a is provided with bevel gears 54b and 54c, respectively, and the rotating shafts 56a and 57a are also provided with bevel gears 56b and 57b, respectively, and the bevel gears 54b and 54c and the bevel gears 56b and 57b are engaged with each other. 54a and 55a are synchronously driven by the motor M via the chain C, and therefore the rotary shafts 56a and 57a are also synchronously driven. The other ends of the rotating shafts 56a and 57a are supported by bearings 58a and 58b.
As shown in FIG. 9C, a pair of short endless conveyors 59a and 59b having the same structure as the endless conveyors 54 and 55 may be arranged orthogonally. In this case, the molding can be performed more precisely and the dimensional accuracy is improved.
As shown in FIG. 9D, it can be manufactured using four-sided molding. Further, as shown in FIG. 9E, three-side molding can be performed using this. That is, depending on the type of three-dimensional network structure, if two dies are provided and the filaments are extruded in parallel, the production efficiency is doubled.

As shown in FIG. 10A, as a modified form, instead of the above-described synchronous drive, a drive source (motor or the like) is provided, respectively, and endless conveyors 64 and 65 and rolls 66 and 67 (which may be an endless conveyor) It is also possible to adopt a configuration in which these are driven independently. That is, in the case of three-sided or four-sided molding, the endless conveyors 64 and 65 having the rotation shafts 64a and 65a, and the endless conveyors 64 and 65 can be rotated with their rotation axes orthogonally arranged at the longitudinal ends. A pair of rolls 66 and 67 having rotating shafts 66a and 67a are arranged. The rotating shafts 66a and 67a are each provided with a motor M and are driven independently. The other ends of the rotary shafts 66a and 67a are supported by bearings 68a and 68b.
As another modification, as shown in FIG. 10B, the pair of rolls 66 and 67, the rotating shafts 66a and 67a, the bearings 68a and 68b, and the motor M are deleted in the above-described example, and polytetrafluoroethylene is processed on the surface. By providing the slidable curved plates 69a and 69b in which the rolls 66 and 67 are located, the drive mechanism can be simplified. The curved plates 69a and 69b are arcuate in a side view, set so that the interval gradually decreases from the upper part to the lower part, and are formed in a rectangular shape in plan view.

The hole of the cap 34 is descending in series, and there is a hole from which the thread descends downward. It may be equally spaced or non-equally spaced. The holes can have various arrangements such as a staggered shape or an orthogonal shape. When it is desired to change the arrangement density, a method of actively increasing the density only in the end region may be used. Various requirements of products can be satisfied by variously changing the shape of the base. For example, a base 71 in which about 3500 holes H having a diameter of 0.5 mm are formed at approximately equal intervals in an area of 1.0 m × 180 mm (the range of the size of the area provided with the holes H of the base is the area of the base 71) (See FIG. 11 (a)), the base 72 (see FIG. 11 (b)) in which the density of the holes H is increased only in the peripheral portion 72a, and the density of the frame-like portion 73b so as to form a grid-like region. A base 73 (see FIG. 11 (c)) with an increased height, and a base 74 (see FIG. 11 (d)) in which slits (linear through-holes) 74 a to 74 c are formed in parallel to the short direction in addition to a large number of holes H. In addition to the many holes H, a base 75 (see FIG. 11E) in which a slit (linear through hole) 75a is formed in the center in the longitudinal direction, and in addition to the numerous holes H, slits (linear) A base 76 (through-hole) 76a formed at a position close to the side in the longitudinal direction (see FIG. 11 (f)) In order to create a hollow portion, a base 77 provided with rectangular guide members (pipe, etc.) 77a, 77b which are formed with regions 77c, 77d not provided with holes H at the corresponding locations and which extend downward at the bottom of the regions. 77 (see FIGS. 11 (g) and 11 (h)) can be implemented. The density of the holes H formed in the die is preferably 1 to 5 / cm ² .

(Method for producing a three-dimensional network structure)
The three-dimensional network structure 1 is manufactured as follows. First, recycled PET bottle flakes may be heated and dried to prevent hydrolysis, and an agent for improving the finish or an antibacterial agent may be added thereto. When the filament is lowered flat from the base 34, it is wound spirally by the winding action of the endless members 12, 13 of the endless conveyors 14, 15. It winds in from the place which contacted the surface of the endless members 12 and 13 when winding. The part that is caught is high in density, and the part that is not caught is low in density.

Next, as shown in FIG. 6, the molten thermoplastic resin is extruded downward from the plurality of dies 33 and is naturally lowered between a pair of endless conveyors 14 and 15 that are partially submerged, and taken slower than the above-described descent speed. When manufacturing the three-dimensional network structure 1 which is a three-dimensional network structure, the distance between the pair of endless conveyors 14 and 15 is narrower than the width of the extruded molten resin aggregate, and the endless conveyors 14 and 15 are submerged. Before and after the process, both sides or one side of the molten resin aggregate were brought into contact with the endless conveyors 14 and 15.
Since both sides or one surface portion of the molten thermoplastic resin aggregate fall on the endless conveyors 14 and 15 and move to the inside of the molten thermoplastic resin aggregate, it becomes a dense state. The porosity is smaller than the dropped central part. Naturally, the surface portion where the porosity is low has more intersections than the central portion where the porosity is high, and the tensile strength is significantly increased. Further, the surface portion having a low porosity has a small area of the void portion, and becomes a shock absorbing layer and a soundproof layer.

In order to function as the three-dimensional network structure 1, the overall porosity was determined to be in the range of 50% to 98% porosity although it depends on the field construction conditions used. That is, it is considered that the sound is blocked when the density is high. The results showed that the porosity should be at least 70% or more in order to exhibit sufficient functions as a recycled sound-absorbing building material, cushioning material, heat insulating material and the like. That is, if the porosity is less than 70%, the impact absorption effect, the soundproof effect, the heat insulation effect, and the cushioning property may not be improved as expected. About this porosity, it is good to design suitably in 70%-98% of range according to the use of the solid network structure 1.
The sound absorbing material and the cushioning material are preferably 85 to 98%, the floor impact absorbing material disposed under the floor is 40 to 80%, and the impact absorbing material for preventing collision is preferably 60 to 90%. The preferred range of porosity varies depending on the application.
Porosity = 100 − {(B ÷ A) × 100}. A is the resin specific gravity multiplied by the volume of the three-dimensional network structure, and B is the weight of the three-dimensional network structure.
As the thermoplastic resin used here, a PET bottle is pulverized into flakes as a raw material or a main raw material. However, there is no problem as long as the main raw material is a resin that can be processed by a normal extrusion molding machine, such as a polymer such as polypropylene or a blend of a plurality of polymers.

The process of forming the deformed three-dimensional network into a product shape was made such that the internal pressure of the die was made uniform, and the take-up surface was taken in two, three, four, or intermediate portions. As a result, an apparent density of 0.02 to 0.9 g / cm ³ is made possible, the melted filament is changed from a disordered spiral shape to a flat plate shape, and the thickness, front, rear, left end, and right end surfaces are solid. The surface portion of the net-like structure has a flat and irregular shape. A variety of three-dimensional network structures can be formed by combining a die base shape for forming a three-dimensional network structure with a round bar, an irregular shape (pipe, Y shape), or a combination thereof. Further, the three-dimensional network structure is made into a super dense structure sheet structure by roll compression of a take-up machine. Contact with a take-up conveyor that forms a shape on the conveyor on three or four sides of the molten resin aggregate that is extruded when the recycled PET resin is uniformly discharged from the die and the three-dimensional network sheet is produced. I tried to do it. That is, the molten recycled PET resin aggregate is formed into a shape corresponding to the product shape on the three or four surface portions. For example, if necessary, a resin aggregate is taken up on a polygonal conveyor to form a product. One method of obtaining a three-dimensional net-like sheet is to push downward from a plurality of molten resin dies and naturally descend between the water surface or a partially submerged conveyor to create a random spiral shape and create a three-dimensional net-like sheet. It becomes.
When the width of the sheet was 1.0 m and the thickness was 100 mm, it was confirmed that the density changed by changing the speed of the endless conveyor in order to confirm that the density changed.

Furthermore, it was confirmed that the density changed due to the change of the discharge amount of the extruder.
A die 34 having an area of 1.0 m × 180 mm and a die 34 having a diameter of 0.5 mm and having approximately 3500 holes H at approximately equal intervals were attached to a single screw extruder having a screw diameter of 75 mm. A water tank 18 having a water level is installed at a position of about 120 mm below the die 33, and a pair of endless conveyors 14 and 15 having a width of 1.2 m are spaced apart by 50 mm, and the upper parts of the endless conveyors 14 and 15 are about 40 mm from the water surface. It was installed almost vertically so that it could come out.
With this apparatus, the temperature of the die 33 is controlled so that the resin temperature becomes 240 ° C. while plasticizing the recycled PET resin by applying heat, and the molten resin discharged from the die 34 at an extrusion amount of 120 kg per hour is controlled. The assembly was extruded between them so that both sides of the assembly fell on the endless conveyors 14 and 15. The take-up speed of the endless conveyors 14 and 15 at this time was 0.7 m / min. The molded product that has been sandwiched between the endless conveyors 14 and 15 and moved downward changes its direction at the lower part of the water tank 18, moves from the side opposite to the extruder to the water surface, and when it exits the water tank 18, either compressed air or Water was blown away with a vacuum pump.
The thus obtained three-dimensional network structure has a width 1.0 m, a thickness of 50 mm, ^{density, 0.07g / cm 3 ~0.14g / cm} 3 was obtained. Applications include heat insulating materials, base materials, sound absorbing materials, drain pipes, and the like.

According to the three-dimensional network structure 1 and the three-dimensional network structure manufacturing apparatus 10 described above, finishing in a later process is unnecessary, the degree of alignment is increased, and it is possible to cope with irregular shapes, thereby improving durability. it can.
Further, according to the present embodiment, it is considered that PET bottles that are not currently used can be used as a three-dimensional network structure, and the recovery rate of PET bottles is increased. This greatly facilitates PET bottle recycling.

  FIG. 12 shows a modified form of the four-sided three-dimensional network structure manufacturing apparatus 50. FIG. 12 (a) corresponds to FIG. 9 (b), and the surface of the pair of rolls 56, 57 is single or A plurality of protrusions 90a to 90c are formed (the roll 57 and its protrusions are not shown). This is to form a dent on the side surface of the three-dimensional network structure. The protrusions 90a to 90c have a square cross section and are formed in an arc shape. Theoretically, the dent should be square, but the resin thread falls from the top as described above, so a blind can be made, and an area that does not contain the resin thread is actually created. The dent on the side of the structure is curved. In other words, it feels like taking an Earl. FIG. 12B corresponds to FIG. 9C, in which one or a plurality of protrusions 96 are formed on the surface of the pair of endless conveyors 54 and 55 described above (endless conveyor). 55 and its protrusions are not shown). Further, a cam and a spring are put in a rotating body such as the rolls 56 and 57 or the endless conveyors 54 and 55 described above, and the cam pushes the protrusion outward in synchronization with the rotation of the protrusion. The blinds can be reduced and more precise recesses can be formed. Since other structures are the same as those in FIGS. 9B and 9C, the illustration and description are incorporated.

Next, a second embodiment will be described. The demand for recycling of three-dimensional network products is diversified and may not be able to meet the current situation. For example, when two or more types of resins are mixed and recycled, there are raw materials that can be separated and raw materials that cannot be separated at the time of recycling. However, recycling may become impossible in practice. Moreover, even if it is the same raw material, there are cases where it is desired to change the shape, such as when it is desired to form a dense or dense structure, when a hollow portion is to be formed later, or to improve the formability.
Therefore, the present embodiment aims to prevent troubles in recycling of the thermoplastic resin and to enable easy change of the shape.

As shown in FIG. 13A, the three-dimensional network structure 101 of the tenth embodiment uses a recycled thermoplastic resin as a raw material or a main raw material, and a plurality of filaments are spirally and randomly entangled and partially thermally bonded. It is a three-dimensional network structure characterized by being a plate-shaped three-dimensional network structure. Moreover, it is comprised from the inner side area | region 101a and the outer side area | region 101b from which the raw material is the same or different. The boundary between the inner region 101a and the outer region 101b is indicated by a solid line. This solid line is a virtual line for indicating the boundary, and the same applies to other embodiments described below. It is preferable that the density on the surface side of the two, three, or four surfaces of the three-dimensional network structure is relatively higher than the density of the portion excluding the surface side. That is, the three-dimensional network structure 101 (see FIG. 13A) of the tenth embodiment is a two-sided molding, and a region at a predetermined interval is formed with a high density from the opposite one surface toward the inside. The density of the region inside the central portion is set lower than that, and the other surface is uneven. For this reason, the advantage which does not process in a post process arises. That is, a pair of wide surfaces and one side surface are forcibly formed by an endless conveyor or the like, which will be described later, and the edges are aligned more cleanly than the other surfaces.
The three-dimensional network structure 102 (see FIG. 13 (b)) of the eleventh embodiment is a three-sided molding, and all surfaces are aligned except for the end surface and one side surface, and from all the surfaces except the right side surface to the inside. On the other hand, the regions at predetermined intervals are formed with high density. Moreover, the raw material is comprised from the inner side area | region 102a and the outer side area | region 102b which are the same or different.
The three-dimensional network structure 103 (see FIG. 13C) of the twelfth embodiment is a four-sided molding, and all the surfaces are aligned except for the end faces. From the left and right side surfaces of the three-dimensional network structure 1 of the first embodiment. A region at a predetermined interval toward the inside is formed with a high density, and the density of the region inside the central part is set lower than that. That is, the regions at predetermined intervals from all the side surfaces toward the inside are formed with high density. Moreover, the raw material is comprised from the inner side area | region 103a and the outer side area | region 103b which are the same or different.
The three-dimensional network structure 104 (see FIG. 13D) of the thirteenth embodiment is provided with a single or plural (here, one) hollow portion 104c, and is intended to further reduce costs. Is. Moreover, the raw material is comprised from the inner side area | region 104a and the outer side area | region 104b which are the same or different.

The three-dimensional network structure 105 (see FIG. 14A) of the fourteenth embodiment is composed of three layers 105a, 105b, and 105c of the same or different raw materials. The raw materials of the three layers may be all different, or the region 105a and the region 105c may be the same material and the region 105b may be different materials. Further, all the raw materials in the three layers may be the same. The three layers 105a, 105b, 105c are divided in the longitudinal direction.
The three-dimensional network structure 106 (see FIG. 14B) according to the fifteenth embodiment is composed of two layers 106a and 106b of the same or different raw materials. The raw materials of the two layers 106a and 106b may be different or the same. The two-layer regions 106a and 106b are divided in the lateral width direction.
The three-dimensional network structure 107 (see FIG. 14C) of the sixteenth embodiment is composed of two layers 107a and 107b of the same or different raw materials. The raw materials of the two layers 107a and 107b may be different or the same. Unlike the fourteenth and fifteenth embodiments, the dividing direction of the region is the thickness direction.
In the case shown in FIG. 3, a sheet 9A having a high density (filled area substantially free of voids) and other areas are formed by separate paths from different extrusion machines, so that a predetermined widthwise direction is obtained. Can be formed in position. The description uses the above.
In addition, although not shown in the drawings, the present invention can be carried out with various irregular cross sections such as a triangular shape and a Y-shaped cross section. As described above, by separately supplying to two or more regions provided in the die, it is easy to adjust the production conditions such as the temperature of the raw material or the extrusion speed of the filament.

Next, the three-dimensional network-structure manufacturing apparatus 110 of 2nd Embodiment is demonstrated.
As shown in FIG. 15, the three-dimensional network structure manufacturing apparatus 110 includes an extruder 111, a pair of endless conveyors 114 and 115 including endless members 112 and 113, a drive motor 116 that drives the endless members 112 and 113, a chain, It is comprised from the gearbox 117 which changes the moving speed of the endless members 112 and 113, the water tank 118 which partially submerses a pair of endless conveyors 114 and 115, the control apparatus 119, and other instruments.
For the endless members 112 and 113, the description of the first embodiment is cited.
As shown in FIG. 15, the extruder 111 includes containers 131a and 131b in which the same or different thermoplastic resin raw materials are stored, raw material supply ports 132a and 132b provided in the upper portions of the containers 131a and 131b, and containers 131a and 131b, respectively. The connected raw material supply pipes 133a and 133b, the raw material supply pipes 133a and 133b and the packing die 134a and 134b are connected to each other and connected to the lower end portion of the composite die 135 (see FIG. 16). It consists of a possible base 136 (see FIG. 16) and the like. The raw material supply pipe 133a is branched into a plurality (four in this case) on the way, and straddles the raw material supply pipe 133b. Further, the lower end portion of the raw material supply pipe 133a is disposed around the lower end portion of the raw material supply pipe 133b. As shown in FIGS. 16A and 16B, the composite die 135 has a frame-shaped partition wall 139 formed in the inner region of the outer frame 138, and divides the interior of the composite die 135 into two chambers 137a and 137b. The same kind of raw material or two different kinds of raw materials supplied via the supply pipe 133a or 133b are not mixed. Even when the raw materials are the same, it is desirable to provide the partition wall 139 in order to adjust the extrusion speed separately. For details of the inside of the die of the extruder 111, the first embodiment is used. Although the raw material supply pipe 133a is branched into four, it may be branched into an appropriate number such as two (see FIG. 17 (a)) and three (see FIG. 17 (b)).

Two or more regions are formed in the base 136 so that raw materials are supplied separately. For this reason, it becomes very easy to adjust the extrusion speed or the extrusion amount of the filament, and the moldability is remarkably improved. For details of the base, the first embodiment is used, but here, the base 171 formed at substantially equal intervals or at appropriate intervals (the range of the size of the area provided with the hole H of the base is the area of the base 171. 90%) (see FIG. 18A). In the base 171, an inner region 171 a and an outer region 171 b are partitioned by a partition wall 171 c indicated by a dotted line, and the same or different raw material filaments are extruded separately corresponding to the raw material supply pipes 133 a and 133 b, respectively. It has become.
An inner region 172a having a large number of holes H and an outer region 172b are partitioned by a partition wall 172c indicated by a dotted line, and the inner region 172a is biased with respect to the outer region 172b, so that the filaments corresponding to the inner region 172a can be easily separated. And the base 172 (see FIG. 18B).
An inner region 173a having a large number of holes H and an outer region 173b are partitioned by a partition wall 173c indicated by a dotted line, and the inner region 173a is sandwiched by the outer region 173b from both sides, and is applicable for creating a hollow portion. Regions 173d and 173e where holes H are not provided are formed, and a base 173 (FIGS. 18C and 18C) provided with rectangular guide members (such as pipes) 173f and 173g extending downward at the lower portions of the regions. d)).

There is a base 174 (see FIG. 19A) that is divided into three layers (three layers) by dividing an upper region 174a having a large number of holes H, a central region 174b, and a lower region 174c by partition walls 174d and 174e indicated by dotted lines. Can be mentioned.
There is a base 175 (see FIG. 19B) in which an upper region 175a and a lower region 175b each having a large number of holes H are partitioned by a partition wall 175c indicated by a dotted line to form two steps (two layers).
Examples include a base 176 (see FIG. 19C) in which a left side region 176a and a right side region 176b each having a large number of holes H are partitioned by partition walls 176c indicated by dotted lines to form two rows (two layers).
A base in which a region 177a having a large number of holes H and a slit (straight groove) 177b formed at an appropriate position such as a central portion in parallel with a predetermined direction (here, the longitudinal direction) is partitioned by a partition wall 177c indicated by a dotted line 177 (see FIG. 19D). The slit 177b exists in the region of the partition 177c. The groove width, length, or position of the slit (straight groove) 177b can be selected as appropriate. If the raw material is supplied to the region 177a having a large number of holes H and the slit (straight groove) 177b from the same die, the waveform of FIG. According to 177, since the raw materials are separately and independently supplied from the two or more types of extruders 111 to the hole H of the region 177a and the slit 177b, a suitable waveform can be obtained. Note that a hole H may be provided instead of the slit 177b. In that case, the density of the holes H should be increased.
Various other specifications can be implemented. The density of the holes H formed in the die is preferably 1 to 5 / cm ² .
The manufacturing method of a three-dimensional network structure uses 1st Embodiment etc.

According to the three-dimensional network structures 101 to 107 of the tenth to sixteenth embodiments, a resin that is difficult to separate or a resin that cannot be separated is the first region 101a, and a resin that can be separated is the second region 101b. By separating this during recycling, it can be repeatedly recycled.
A three-dimensional network structure divided into regions according to the properties of the thermoplastic resin can be manufactured, and the thermoplastic resin can be smoothly recycled. Further, there is an advantage that the shape can be changed later by a simple operation such as separating the regions. In addition, since the raw materials are separately supplied to the die from a plurality of extruders, the formability of the three-dimensional network structure is improved.

The three-dimensional network structure manufacturing apparatus 210 according to the third embodiment avoids inconvenience due to the deformation of the endless belt, eliminates the need for finishing in the subsequent process, increases the degree of alignment, and can cope with irregular shapes, and is durable. An object of the present invention is to provide a manufacturing method and a manufacturing apparatus of a three-dimensional network structure with improved properties.
The three-dimensional network-structure manufacturing apparatus 210 uses the first embodiment or the like and describes different configurations. Extruder 211, a pair of rolls 212 and 213 installed in a horizontal position at a predetermined interval, arranged below the pair of rolls 212 and 213 in alignment with them, and horizontally at a predetermined interval A pair of disposed rolls 214 and 215 (see FIG. 20), a drive motor for driving the rolls 212 to 215, a chain and gears, a transmission for changing the moving speed of the rolls 212 to 215, and a pair of rolls 212 and 213 Is composed of a water tank, a control device, other instruments, and the like in which a part of the rolls 214 and 215 are completely submerged. In FIG. 20, one lower roll may be deleted, and three rolls may be provided.
Examples of the rolls 212 and 213 include a roll 224 having a circular cross section (see FIG. 22A) and a deformed cross section. For example, a roll 225 having a sawtooth cross section on the outer peripheral surface (see FIG. 22 (b)), a continuously formed uneven shape, for example, a roll 226 having an outer peripheral surface having a gear cross section (see FIG. 22 (c)), an outer peripheral surface A roll 227 (see FIG. 22 (d)) having one or more protrusions 227a (for example, triangular or round protrusions) formed thereon, an elliptical cross section roll 228 (see FIG. 22 (e)), a triangle or a rice ball Various modifications are possible, such as a roll 229 with a cross section (see FIG. 22 (f)), a polygonal cross section, for example, a roll 230 with an octagonal cross section (see FIG. 22 (g)).
As shown in FIG. 21, the rolls 212 to 215 include drive shafts 212a to 215a, respectively. The drive shafts 212a to 215a are rotatably supported by respective bearings, and are respectively driven in the direction of the arrow in FIG. 20 by a drive motor via a transmission.
According to the three-dimensional network-structure manufacturing apparatus 210 described above, finishing in a subsequent process is not necessary, the degree of alignment is increased, it is possible to cope with irregular shapes, and durability is improved.

A three-dimensional network structure 401 according to the seventeenth embodiment is obtained by providing coarse and dense structures. Applications can be applied to, for example, wall materials for hanging garden containers, decks on which garden containers are placed, blindfolds, sunshades, awnings, buds, flower cushions, and the like.
The density of the three-dimensional network structure 401 adjusts the conveyance speed of a take-up device, for example, an endless conveyor or a roller, by controlling the rotational speed of the motor. Rather than adjusting the hydraulic pressure of the extruder, stable density can be produced.
As shown in FIG. 23A, a sparse portion 401a and a dense portion 401b are repeatedly formed in order. Further, as shown in FIG. 23B, hollow portions 406A and 406B are provided in a predetermined direction. As a modified form, as shown in FIG. 23 (d), a gardening cushion material 402 having a plurality of small holes 407a to 407d penetrating in the length direction may be used. The density range of the sparse part 401a and the dense part 401b can be set as appropriate. The description of the first embodiment and the like is used for the raw materials of the thermoplastic resin.

As shown in FIG. 24, in order to create a hollow portion in the base 471, regions 477 a and 477 b where holes H are not provided are formed at the corresponding locations, and rectangular guide members (plate material, pipes) that extend downward below the regions are formed. Etc.) 477c and 477d are provided (see FIG. 24B). As another example, a base 481 in which a predetermined number of holes H are formed at almost equal intervals (the range of the size of the region provided with the base hole H occupies 90% of the area of the base 71) (FIG. 24C )), And in order to create a hollow portion, regions 487a to 487d where holes H are not provided are formed at the corresponding locations, and rectangular guide members (plates, pipes, etc.) extending downwardly below the regions are formed. 488a to 488d are provided (see FIG. 24D). The density of the holes H formed in the die is preferably 1 to 5 / cm ² . Many other specifications can be implemented.

The three-dimensional network structure 401 can be used as a substitute for a wall material for hanging a gardening container, a wall for flower decoration, a blindfold, or a fence. For example, as shown in FIG. 25, a pile 480 (which may be a pillar) is driven into the ground to stand, and is inserted into and fixed to the hollow portions 406A and 406B of the three-dimensional network structure 401. The three-dimensional network structure 401 may be divided into a plurality of parts, and dimensions may be freely selected by combining the divided parts. Then, an appropriate number of hanging baskets 482 with hooks 481 are hooked on the sparse portion 401a. It is easier to hook the hook 481 than the dense portion 401b. On the other hand, it can also be used as a deck. For example, the three-dimensional network structure 490 does not have a hollow portion, but is manufactured in the same manufacturing process as the three-dimensional network structure 401, and a cultivation pot 491, a container 492, and the like can be placed thereon. it can. In addition, it can be applied to sunshades, awnings, buds, flower decorations, etc. In addition, as shown in FIG. 26, the three-dimensional network structure 402 can be used as a partition for trees on a roof, a sunshade, and a road median. Each of the small holes 407a to 407c of the three-dimensional network structure 402 can be fixed to the structure by an appropriate means such as passing a connector 403 such as a string, a ring, or a pipe. When used as a partition for trees in the median strip of the road, it has an anti-glare effect on automobile lights.
According to the three-dimensional network structure 401 described above, it can be applied to wall materials for hanging baskets, decks, blindfolds, etc., and the cost is reduced, and it is durable even when exposed to wind and rain or sunlight. There is no warping and the color is less likely to fade. Various colors can be used, coloring is free, the range of color choices is expanded, cushioning is very good, the blinding effect is enhanced, the appearance with different textures can be provided, and it is very convenient .

  The three-dimensional network structure can be applied as a nursery for rooftop greening. Holes or dents are formed at appropriate locations on the air-permeable and water-permeable tiles, a three-dimensional network structure is laid, and a plant is planted by placing cultivation soil in the holes or dents.

  It can also be applied as a pavement material by attaching air permeable and water permeable tiles to the upper surface of the three-dimensional network structure. The temperature can be lowered by the three-dimensional network structure.

  A brittleness-causing material such as a thermoplastic resin containing an inorganic substance such as talc is used as a raw material or main raw material, and a plurality of filaments are entangled in a spiral manner by extrusion and are partially heat-bonded and cooled with a liquid, external force It is also possible to manufacture a three-dimensional network structure characterized by being capable of brittle fracture.

  In addition, a thermoplastic resin is used as a raw material or main raw material, and a plurality of filaments are spirally and randomly entangled by extrusion, partially heat-bonded and cooled with a liquid, a flame-retardant material is applied, or a carbon fiber nonwoven fabric It is also possible to manufacture a three-dimensional network structure in which a flame retardant material is added to a thermoplastic resin. If it is surrounded by a carbon fiber nonwoven fabric or the like, it can be placed behind the ceiling or in the wall.

  As shown in FIG. 27, a three-dimensional network structure manufacturing apparatus 510 according to the fourth embodiment forms a three-dimensional network structure 501 with curved plates 582 and 583 instead of endless members and rolls. The curved plates 582 and 583 are extended perpendicular to the paper surface, and the surface is made slippery by a polytetrafluoroethylene coating or the like. The side view is rectangular. The curved plates 582 and 583 have a structure in which the interval gradually decreases from the upper part to the lower part. The curved plates 582 and 583 may have a fixed structure, or, as indicated by the dotted lines, by changing the distance between them by reciprocating drive devices 590 and 591 (for example, fluid pressure cylinders), The density, shape, etc. can be changed. A curved plate 584 is also provided below the curved plates 582 and 583 to appropriately guide the three-dimensional network structure 501 to the downstream take-up machine.

1 to 9, 101 to 107, 401, 402, 490, 501 ... Three-dimensional network structure 10, 50, 110, 210, 510 ... Three-dimensional network structure manufacturing apparatus 11, 111, 211 ... Extruder 12, 13, 112 113 endless members 14, 15, 54, 55, 59a, 59b, 64, 65, 114, 115 ... endless conveyor 33 ... dice 135 ... composite dice 34, 71-77, 136, 171-177, 471, 481 ... Bases 56, 57, 66, 67, 212 to 215, 224 to 230 ... rolls

Claims (2)

  A molten filament made of a thermoplastic resin as a raw material or a main raw material is extruded downward from a die having a plurality of holes, and is naturally lowered between submerged drawing devices. An apparatus for manufacturing a three-dimensional network structure in which a distance between the drawing devices is set to be narrower than a width of a set of filaments, and the drawing device is arranged so that at least three surfaces or four surfaces of the assembly of wires are in contact with each other.   A molten filament made of a thermoplastic resin as a raw material or a main raw material is extruded downward from a die having a plurality of holes, and is naturally lowered between submerged drawing devices. A method for producing a three-dimensional network structure in which a distance between the drawing devices is set to be narrower than a width of the aggregate of filaments, and the attraction device contacts at least three or four surfaces of the aggregate of filaments.

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