JP6211492B2 - Insole manufacturing method and insole manufacturing device - Google Patents

Description

  The present invention mainly relates to a method for manufacturing an insole used on the inner bottom surface of footwear such as shoes and sandals, and an apparatus for manufacturing the insole. The insole in the present invention includes both an insole that constitutes a part of the inner bottom of the footwear and an insole that is additionally provided on an existing footwear.

  In general, an insole for footwear is one in which a plurality of sheets are laminated and fixed on a flat surface or in a mold. There is a demand in the market for an insole manufacturing method and an insole manufacturing apparatus capable of simplifying the insole manufacturing process and mass production.

  On the other hand, as a means for increasing the production efficiency of the insole, a manufacturing method in which the insole is punched out by a roll has been invented, for example, while sending a material made of woven fabric and a material of foamed polyethylene at a constant speed, While applying a polyethylene solution to the surface of the material, the material and the material are overlapped and laminated with a processing roll to make a composite material. The composite material is fed between a pair of projecting rolls and heated under pressure. Forming a concave and convex surface with a geometric pattern on both sides of the composite material by molding, and then applying glue to the surface of the composite material to create an adhesive surface while feeding the composite material to the next punching process The process of punching a large number of insoles from the composite material by continuously feeding the adhesive surface to the punching roll through a feeding roll while covering the adhesive surface with release paper and passing through the punching roll is performed. Special Geometric patterns like the uneven surface insole manufacturing process in the slippers having a to be known (e.g., see Patent Document 1.).

  Further, as a production method capable of mass production of other insoles, a method for producing insoles using high-frequency welding, which is a fine honeycomb fabric made of vinylidene chloride synthetic resin monofilament, a honeycomb fabric made of vinylidene chloride synthetic resin monofilament Made of woven fabric, vinylidene chloride synthetic resin and / or non-woven fabric composed of vinyl chloride synthetic resin short fiber, mixed latex mixed with activated carbon powder and / or copper powder, and then heat-treated sheet, made of vinylidene chloride synthetic resin monofilament Coarse mesh woven fabric and front sheet are laminated one on top of the other to form a laminate. On the flat bottom electrode of the high-frequency welder, the thickness is 0.02 to 0 mm on 0.1 to 0.5 mm thick paper. Place an insulation cushioning material laminated with a polyester film of 1 mm, and overlay a polyester film with a thickness of 0.01-0.02 mm on top of it. The upper electrode with the inner surface of the convex portion inclined and the outer peripheral portion sharpened is lowered toward the lower electrode, and the buffer material, the laminate, and the film are fixed between the two electrodes, and the high frequency is between the two electrodes. A method for manufacturing an insole is characterized in that a peripheral portion of a laminate is welded through an electric current, and a plurality of cutting lines or broken lines corresponding to each size of a foot are formed by welding, and then punched by punching. (For example, refer to Patent Document 2).

Japanese Patent Laid-Open No. 10-192007 Japanese Patent Publication No.63-13687

  According to the invention according to Patent Document 1, the process itself of punching a sheet with a roll to obtain an insole can contribute to efficient production of the insole, but in order to obtain an insole as a product, as described above , Applying polyethylene solution to the surface of the material, pressurizing and laminating, forming a geometric pattern on both sides of the composite material, applying paste and coating release paper, punching process I must. For this reason, there are disadvantages that a large number of processes increase losses due to problems and the like, and the area occupied by the facilities also increases.

Further, according to the invention according to Patent Document 2, so-called internal heating by high frequency is performed, the peripheral edge of the laminate is welded, and a plurality of cutting lines or cutting broken lines corresponding to each size of the foot are formed by welding. Later, the insole is punched out by a separate means. In order to perform internal heating by high frequency (electromagnetic waves), it was impossible to cut at the same time.
For this reason, there was a limit to the efficiency of the process.

  The present invention has been made in view of the above circumstances. In the production of insoles, the number of processes is reduced as compared with the conventional processes, thereby reducing losses due to defects and the like, and reducing the area occupied by the equipment. An object of the present invention is to provide an excellent insole manufacturing method and manufacturing apparatus capable of improving efficiency.

The present invention relates to a method for manufacturing an insole,
A cylindrical mold roller having a pressing means and a cutting means for the laminated sheets on the circumferential surface, and an ultrasonic oscillator sandwich the laminated sheets, and weld and cut a part of the sheets, A method of manufacturing an insole to be formed, wherein the cylindrical mold roller has a row of guide pressing portions that spread a plurality of stacked sheets in the width direction at least at a plurality of positions on the left and right in the width direction. The guide pressing portion is a convex portion that is arranged closer to the center in the width direction of the cylindrical mold roller than the end portion that intersects the rotation direction and the rear end in the rotation direction is the front end. A method for manufacturing an insole characterized by comprising:

According to the present invention, in addition to the configuration of the above invention, a first step of polymerizing and laminating a plurality of sheets, and a step of simultaneously welding and cutting the laminated sheets by the cylindrical mold roller and the ultrasonic oscillation unit. A second step and a third step of discharging the obtained insole, and the cutting means in the cylindrical die roller has an amount of protrusion from the roller peripheral surface larger than the amount of protrusion of the pressing means, and ultrasonic oscillation parts are a horn having a contact surface, the second step, welding the sheet mutually the convex portion is the multilayer and pressing the stacked sheets on the contact surface of the horn of the ultrasonic oscillation state And a method of manufacturing an insole, wherein a cutting blade portion as the cutting means cuts the laminated sheets on a contact surface of the ultrasonically oscillated horn. Means for this.

  In addition to the configuration of the present invention, the first step has a pair of sheet introduction side rollers for laminating a plurality of sheets, and the third step is a pair of discharge side rollers for discharging the insole. The second step includes a guide portion that guides a bottom surface side of the stacked sheets, and at least one of the pair of sheet introduction side rollers in the first step includes the first step. A method for manufacturing an insole that makes it possible to adjust the distance from the other sheet introduction side roller in the process is a means for solving the problem.

  According to the present invention, in addition to the configuration of the above invention, at least one of the pair of sheet discharge side rollers in the third step adjusts the distance from the other sheet discharge side roller in the third step. A method for manufacturing an insole characterized by being made possible is a means for solving the problems.

  In addition to the configuration of the invention described above, the present invention provides an insole that is a sheet containing a sheath-core monofilament thread formed by coating the surface of a monofilament with a low-melting polymer on at least one of the laminated sheets. In order to solve the problems, the manufacturing method of the insole is characterized in that the low melting point polymer on the surface of the sheath-core monofilament is melted and fixed in addition to the effects of the above-described invention because of the manufacturing method. Means.

Also, a pair of sheet introduction side rollers for introducing a plurality of sheets in a stacked manner, and a cylindrical mold roller having pressing means and cutting means on the peripheral surface for melting and cutting the plurality of stacked sheets And an ultrasonic oscillating unit and a pair of discharge side rollers for discharging the insole in order from the upper process to the lower process, and the bottom surface side of the stacked sheets is disposed between the sheet introduction side roller and the discharge side roller. It is provided with a guide portion for guiding, and the cylindrical die roller is provided with a plurality of guide pressing portions that extend the plurality of stacked sheets in the width direction at least at a plurality of positions on the left and right sides in the width direction. The guide pressing part has a convex part that is arranged closer to the center in the width direction of the cylindrical mold roller than an end part that intersects the rotation direction and is rearward in the rotation direction. Made insole The apparatus and means for solving the problems.

  In addition to the construction of any one of the above insole manufacturing apparatuses, the present invention provides a sheet introduction side gear at one end of the pair of sheet introduction side rollers, and a mold at one end of the cylindrical mold roller. Each of the sheet introduction side gears directly or indirectly from the drive gear. An insole manufacturing apparatus in which power is transmitted to the mold gear and each discharge side gear and the sheet introduction side roller, the cylindrical mold roller, and the discharge side roller are operated is a means for solving the problem.

According to the present invention, the laminated sheet is sandwiched between a cylindrical mold roller having a pressing means and a cutting means for the laminated sheet on the peripheral surface, and an ultrasonic oscillator, and a part of the sheet is welded and By cutting and forming the insole, it is possible to shorten the process by welding and cutting the sheets laminated by the cylindrical mold roller and the ultrasonic oscillation unit. Etc. can be reduced.
In addition, as the process is shortened, a dedicated space for facilities required for each process becomes unnecessary, and the dedicated area of the facilities can be reduced.
Furthermore, an effect of improving the production efficiency of the insole can be obtained by shortening the processing time as the process is shortened.
The cylindrical die roller is provided with guide pressing portions arranged to extend the plurality of stacked sheets in the width direction at least at a plurality of positions on the left and right in the width direction on the circumferential surface, and the guide pressing portions Is a method of manufacturing an insole that has a convex portion that intersects the rotational direction and has an end that is rearward in the rotational direction and located closer to the center in the width direction of the cylindrical mold roller than the end that is the front . Therefore, when a plurality of stacked sheets are sandwiched and transferred between the contact surfaces of the cylindrical mold roller and the horn, the guide pressing portion is in a direction intersecting the rotation direction in a plurality of regions in the width direction of the sheet. Accordingly, the sheet can be pulled to the left and right outwards, so that defects such as leaning and biting of the sheet can be suppressed.

According to the invention of claim 2, in addition to the configuration of the invention described above, a first step of polymerizing and laminating a plurality of sheets, welding of the laminated sheets by the cylindrical mold roller and the ultrasonic oscillation unit, A second step of simultaneously performing cutting and a third step of discharging the obtained insole, and the cutting means in the cylindrical die roller has a protruding amount from the roller peripheral surface larger than the protruding amount of the pressing means. There, an ultrasonic oscillation unit is a horn with a contact surface, the second step, the stacked by pressing the sheet in which the convex portion is the stacked on the contact surface of the horn of the ultrasonic oscillation state In addition , the cutting blades as the cutting means cut the laminated sheets on the contact surface of the ultrasonically oscillating horn to cut the laminated sheets. The product by the contact surface of the horn and the pressing means Compared with the force for holding the sheet, the force for holding the stacked sheet by the contact surface of the horn and the cutting means is increased, and it is easy to cut by ultrasonic oscillation from the contact surface of the horn. it can. Further, the laminated sheets can be welded to each other by an appropriate clamping force between the contact surface of the horn and the pressing means and ultrasonic oscillation from the contact surface of the horn at the location.

  According to the invention of claim 3, in addition to the configuration of the invention described above, the first step has a pair of sheet introduction side rollers for laminating a plurality of sheets, and the third step discharges the insole. A pair of discharge side rollers, the second step has a guide portion for guiding the bottom surface side of the stacked sheets, and at least one of the pair of sheet introduction side rollers of the first step is a sheet introduction side roller Is a method of manufacturing an insole that allows adjustment of the distance from the other sheet introduction side roller in the first step, and in addition to the effects of the invention, the types and number of sheets to be laminated The distance between the pair of sheet introduction side rollers can be adjusted according to the thickness, and a wide layer structure can be realized in the production of the insole.

  According to the invention of claim 4, in addition to the configuration of the invention described above, at least one sheet discharge side roller of the pair of sheet discharge side rollers in the third step is the other sheet discharge side roller in the third step. The insole manufacturing method is characterized in that the distance between the insole can be adjusted and the insole manufactured according to the type, number, and thickness of various sheets to be laminated is discharged in an appropriate state. can do.

  According to the invention of claim 5, in addition to the structure of the invention described above, at least one of the laminated sheets includes a sheath core monofilament yarn in which the surface of the monofilament is coated with a low melting point polymer. In addition to the effects of the invention described above, the insole manufacturing method is an insole manufacturing method in which the low melting point polymer on the surface of the sheath core monofilament is melted and fixed. In addition to the operational effects, the low melting point polymer on the surface of the sheath-core monofilament can be melted and fixed, so that it is not necessary to use an adhesive or the like, and loss such as problems due to shortening of the process can be reduced.

According to the invention of claim 6, a pair of sheet introduction side rollers for introducing and laminating a plurality of sheets , and a pressing means and a cutting means for melting and cutting the plurality of laminated sheets. A cylindrical mold roller and an ultrasonic oscillator provided on the top and a pair of discharge side rollers for discharging the insole are sequentially provided from the upper process to the lower process, and are laminated between the sheet introduction side roller and the discharge side roller. Since the insole manufacturing apparatus is provided with a guide unit that guides the bottom side of the formed sheet, the laminated sheet is sandwiched between the cylindrical mold roller and the ultrasonic oscillation unit, and a part of the sheet is melted and Since the insole can be continuously cut and discharged, the process can be shortened by performing the welding and cutting of the laminated sheets by the cylindrical mold roller and the ultrasonic oscillation unit. No It can be reduced.
In addition, as the process is shortened, a dedicated space for facilities required for each process becomes unnecessary, and the dedicated area of the facilities can be reduced.
Furthermore, the effect of improving the production efficiency can be obtained by shortening the processing time as the process is shortened.
The cylindrical die roller is provided with guide pressing portions arranged to extend the plurality of stacked sheets in the width direction at least at a plurality of positions on the left and right in the width direction on the circumferential surface, and the guide pressing portions Since the end portion that intersects the rotation direction and is rearward in the rotation direction has a convex portion that is disposed closer to the center in the width direction of the cylindrical mold roller than the end portion that is the front side, When the stacked sheets are transported by being sandwiched between the contact surfaces of the cylindrical mold roller and the horn, the sheets are moved along the direction in which the guide pressing portion intersects the rotation direction in a plurality of regions in the width direction of the sheets. Since it acts so as to be pulled appropriately left and right, it is possible to suppress defects such as wrinkling and biting of each part of the sheet.

  According to the invention according to claim 7, in addition to the configuration of the invention of the insole manufacturing apparatus, a sheet introduction side gear is provided at one end of each of the pair of sheet introduction side rollers, and one end of the cylindrical mold roller is provided. A mold gear is provided, a discharge gear is provided at each end of the pair of discharge rollers, a drive gear for transmitting power from a drive source is provided, and each sheet is introduced directly or indirectly from the drive gear. Since the power is transmitted to the side gear, the mold gear, and the discharge side gears, the insole manufacturing apparatus in which the sheet introduction side roller, the cylindrical mold roller, and the discharge side roller operate is provided. Moreover, handling can be facilitated by controlling each gear from one power source.

It is left side explanatory drawing which shows the insole manufacturing apparatus which concerns on the Example of this invention, and the introduction state of each sheet | seat to this manufacturing apparatus. It is a perspective view which shows the manufacturing apparatus of the insole which concerns on the Example of this invention. FIG. 3 is a schematic right perspective view showing the relationship among gears, rollers, guide plates, and ultrasonic oscillators in the insole manufacturing apparatus according to the embodiment of the present invention. It is the front view which shows the outline of the cylindrical metal mold | die roller of the manufacturing apparatus of the insole which concerns on the Example of this invention, and its partially expanded view. It is a top view which shows the relationship between the laminated | stacked sheet | seat processed with the manufacturing apparatus of an insole which concerns on the Example of this invention, an insole, the embossing of an insole, a cutting line, and a separation piece. It is a top view which shows the relationship between the laminated | stacked sheet | seat processed with the manufacturing apparatus of an insole which concerns on the other Example of this invention, the insole, the embossing of an insole, a cutting line, and a separation piece.

In the present invention, the laminated sheet is sandwiched between a cylindrical die roller having a pressing means (pressing part) and a cutting means (cutting blade part) on the peripheral surface, and an ultrasonic wave oscillating part. A part of the sheet is welded and cut to form an insole, and at that time, a first step of polymerizing and laminating a plurality of sheets, the lamination by the cylindrical mold roller and the ultrasonic oscillation unit Welding and cutting of the stacked sheets by the cylindrical mold roller and the ultrasonic oscillation section by providing a second step of simultaneously welding and cutting the sheet and a third step of discharging the obtained insole. By performing the process together, the process can be shortened, the loss of defects due to the shortening of the process can be reduced, the area occupied by the equipment can be reduced, and the effect of improving the production efficiency can be obtained. Ultrasonic oscillation Cut when performing together cleavage of partial welding, the insole periphery contour of the sheets stacked, the protruding amount from the protrusion and the convex portion to be used for welding on the circumferential surface of the cylindrical mold roller larger by the By providing a cutting blade portion as a means, the ultrasonic oscillation portion is a horn having a contact surface,
In the second step of welding / cutting the laminated sheets, the convex portions press the laminated sheets on the contact surface of the horn in an ultrasonic oscillation state to weld the laminated sheets to each other. In addition, since the cutting blade portion cuts the stacked sheets on the contact surface of the ultrasonically oscillating horn, the cutting of the contour shape of the insole and the desired position of the insole Since the insole can be manufactured very efficiently by performing welding of the sheets at the same time, and at least one of the laminated sheets is a sheet that can be thermally welded. The sheet was melted by an ultrasonic wave oscillating unit, and an insole manufacturing method capable of manufacturing efficiently without using an adhesive was realized.

The present invention also provides a cylindrical metal plate having a pair of sheet introduction side rollers for introducing and laminating a plurality of sheets , and a pressing means and a cutting means on the peripheral surface for welding and cutting the plurality of laminated sheets. The cylindrical die roller and the ultrasonic oscillator are provided with a mold roller and an ultrasonic oscillator, and an insole manufacturing apparatus that sequentially includes a pair of discharge-side rollers for discharging the insole from the upper process to the lower process. By sandwiching the stacked sheets, a part of the sheets can be melted and cut, and the insole can be discharged continuously, so that the stacked sheets can be welded and cut by the cylindrical mold roller and the ultrasonic oscillator. This process can shorten the process, and the shortening of the process can reduce the loss of defects, etc., and the shortening of the process eliminates the need for dedicated space for equipment required for each process, and also reduces the dedicated area of the equipment. , By the processing time is shortened with the shortening of the extent, it is possible to obtain an effect of improving the production efficiency,
Between the sheet introduction side roller and the discharge side roller, a guide portion that guides the bottom surface side of the stacked sheets, and a horn having an abutment surface as an ultrasonic oscillation portion, so that the entire bottom surface of the stacked sheets The part that presses the sheet by the pressing means and the cutting means of the cylindrical mold roller can maintain sufficient contact with the horn while the guide part shape is being transferred, so that the quality of the insole as a product can be ensured. A pair of sheet introduction side rollers, each provided with a sheet introduction side gear, each cylindrical mold roller provided with a mold gear, and each pair of discharge side rollers provided with a discharge side gear. A drive gear for transmitting power from the drive source is provided, and power is directly or indirectly transmitted from the drive gear to each sheet introduction side gear, mold gear, and each discharge side gear. La, cylindrical mold roller and the discharge-side roller that is intended to run, by controlling the gears from one power source, it is possible to facilitate handling,
The cylindrical die roller is provided with a guide pressing portion for expanding and spreading a plurality of stacked sheets in the width direction in the vicinity of both ends on the peripheral surface, and the guide pressing portion is at least in the width direction on both the left and right sides. Since the insole manufacturing apparatus is formed with two or more rows at a predetermined interval, when a plurality of stacked sheets are sandwiched between the cylindrical mold roller and the contact surface of the horn and transferred, the sheets are appropriately left and right outward. Since it acts so as to pull, an insole manufacturing apparatus that can suppress defects such as wrinkling and biting of each part of the sheet has been realized.

  The insole manufacturing method and the insole manufacturing apparatus 1 according to the embodiment of the present invention will be described below. The white arrows in FIGS. 1 to 3 indicate the direction in which the sheet is introduced into the manufacturing apparatus 1.

The insole manufacturing apparatus 1 according to the present embodiment is disposed in a lower process of a sheet supply line that supplies two sheets. Specifically, as shown in FIG. 1, it arrange | positions behind the conveyor 2 for carrying in.
In this embodiment, the upper sheet 30 is a bore fabric formed by raising a polyester sheet, and the lower sheet 40 is a polyester nonwoven fabric.

As shown in FIGS. 1 and 2, the insole manufacturing apparatus 1 according to the present embodiment has a pair of sheets that are arranged vertically on the upper process side in a main body portion constituted by a metal frame member and a plate member. An introduction side roller (the upper side is a first introduction side roller 11a and the lower side is a second introduction side roller 11b) and a pair of discharge side rollers arranged vertically on the lower process side for discharging the insole as a product (The upper side is the first discharge side roller 12a and the lower side is the second discharge side roller 12b.) And the cylindrical mold roller disposed between the first sheet introduction side roller 11a and the first discharge side roller 12a. 10 and a horn 13 which is an ultrasonic oscillator disposed below the cylindrical mold roller 10.
The insole manufacturing apparatus 1 includes an operation unit including switches necessary for operation and an ultrasonic oscillator 19.

Each of the rollers has a configuration for cooperating simultaneously by supplying power from a power source.
As shown in FIG. 3, the first introduction side roller 11a has a right end at the first introduction side gear 110a, the second introduction side roller 11b has a right end at the second introduction side gear 110b, and the right end of the first discharge side roller 12a. Is provided with a second discharge side gear 120b at the right end of the first discharge side gear 120a and the second discharge side roller 12b.
A mold gear 100 is provided at the right end of the cylindrical mold roller 10. A drive gear 150 a that meshes with the mold gear 100 is provided below the mold gear 100. An intermediate gear that meshes with the drive gear 150a is provided before and after the drive gear 150a (the upper process side is the first intermediate gear 150b and the lower process side is the second intermediate gear 150c).

  The diameter of the first introduction side gear 110a is formed larger than the diameter of the first introduction side roller 11a. The diameter of the second introduction side gear 110b is formed larger than the diameter of the second introduction side roller 11b. The first introduction side gear 110a and the second introduction side gear 110b mesh with each other. The first intermediate gear 150b and the second introduction side gear 110b mesh with each other.

  Similarly, the diameter of the first discharge side gear 120a is formed larger than the diameter of the first discharge side roller 12a. The diameter of the second discharge side gear 120b is formed larger than the diameter of the second discharge side roller 12b. The first discharge side gear 120a and the second discharge side gear 120b mesh with each other. The second intermediate gear 150c and the second discharge side gear 120b mesh with each other.

The second introduction side roller 11b and the second discharge side roller 12b are held by the first intermediate gear 150b and the second intermediate gear 150c by bearings formed by drilling in the main body.
Each of these gears is stored in the gear storage 15 of the main body.

Further, the rotational speed of the drive gear 150a can be adjusted via the power transmission belt 150d by controlling the output of the motor with the operation unit in the manufacturing apparatus according to the present embodiment. At the same time, the rotational speed of each gear driven from the drive gear 150a is similarly adjusted. Control of the output of the motor, that is, adjustment of the rotation speed of the gear is performed using a speed adjustment knob provided in the operation unit of the manufacturing apparatus 1. With this configuration, the gear speed can be controlled in accordance with the type, number, and thickness of various stacked sheets s constituting the insole.
In this embodiment, it can be stably operated even at a processing speed of approximately 20 to 30 sheets / minute.

  As shown in FIGS. 1 and 2, two guide plates (an upper process side guide plate 14a and a lower process side guide plate) constituting a guide portion between the first introduction side roller 11a and the first discharge side roller 12a. 14b) is arranged horizontally in the front-rear direction. A gap is formed between the two guide plates, and the horn 13 that is an ultrasonic wave oscillating portion is disposed in the gap and at a position near the upper process side guide plate 14a. The horn 13 is positioned lower than the guide plate with the contact surface 13a facing upward.

  The ultrasonic oscillator 19 attached to the insole manufacturing apparatus can be controlled so as to perform optimum welding and cutting in accordance with the material and thickness of the laminated sheets. Control can be performed by operating an adjustment switch in the ultrasonic oscillator 19.

As shown in FIG. 4, the cylindrical mold roller 10 according to this embodiment includes guide blocks 16 at both ends, and further includes a mold gear at one end. The cylindrical mold roller 10 is designed to take an insole for one foot on the left and right.
That is, the cutting blade portion 102 that is a cutting means that cuts and forms the contours of the left and right insoles, and the selected contour line that is a guideline for the user to cut later according to the size of the user's feet are formed as embossing. A pressing portion 101 that is a pressing means for performing the above and a guide pressing portion 103 for reducing or preventing the sheet from being stacked are formed on the peripheral surface of the cylindrical mold roller 10.

The cutting blade portion 102 in the cylindrical die roller 10 is provided at the contour forming position of the insole. The pressing portion 101 is provided in the insole forming position in order to form an emboss on the insole. The guide pressing portion 103 is provided with the entire sheet s laminated in two rows on the left and right sides as a range for preventing wrinkles, except for the insole forming portion.
The cutting blade portion 102 and the pressing portion 101 are different in height from the surface of the cylindrical mold roller 10, and the cutting blade portion 102 is formed to be about 4 mm higher than the pressing portion 101.
Further, the tip of the cutting blade 102 is made of special steel, and the cutting of the sheet under an ultrasonic oscillation state is made favorable and the durability is improved.

  Further, the layout of the cutting blade portion 102 is such that the left and right insole positions are shifted back and forth. With this layout, a large size insole can be obtained with a smaller cylindrical mold roller (ie, a smaller area sheet).

  The first introduction side roller 11a and the first discharge side roller 12a include a guide block 16 on one end side. The other end side is provided with a guide block 16, and the first introduction side gear and the first discharge side gear 120a are provided on the tip side thereof. Four guide frames 17a for guiding the guide block 16 are installed in the main body. Of the spaces between the guide frames 17a, the guide block 16 of the first introduction roller 11a is guided to the space on the upper process side. The guide block 16 of the cylindrical mold roller 10 is guided in the central space. The guide block 16 of the first discharge side roller 12a is guided into the space on the lower process side.

A handle holding member 17b is bridged at the upper ends of the pair of guide frames 17a, and a female screw hole passes through the center of the handle holding member 17b. The guide block 16 can be moved vertically along the guide frame 17a by a handle 18 separately provided above, and can be fixed.
Here, the handle shaft 180 of the handle 18 is a male screw. The handle shaft is threaded through the female screw hole. Furthermore, the tip of the handle shaft 180 is configured to be screwed with a female screw 16 a formed on the guide block 16.
Therefore, depending on the position of the handle holding member 17b and the handle shaft 180, and the position of the handle holding member 17b and the guide block 16, the first introduction side roller 11a, the cylindrical mold roller 10 connected to the guide block 16, and The height of the first discharge side roller 12a can be determined.

Using the insole manufacturing apparatus 1 having the above configuration, the insole is manufactured by the following steps.
A roll of bored fabric (upper sheet roll 3) and a lower sheet 40 arranged on the introduction side are polymerized on a conveyor 2 for carrying in a nonwoven fabric sheet roll (lower sheet roll 4) containing polyester yarn, respectively. The plurality of superposed sheets are introduced between the first sheet introduction side roller 11a and the second sheet introduction side roller 11b of the floor manufacturing apparatus 1.
In this state, the power source of the insole manufacturing apparatus 1 is turned on.

When the power is turned on, the power source is driven, and power is transmitted to the drive gear 150a via the power transmission belt 150d (or chain).
When the drive gear 150a is driven from a power source (not shown) via a power transmission belt 150d (or chain), the mold gear 100, the first intermediate gear 150b, The second intermediate gear 150c follows.
The second introduction side gear 110b meshing with the first intermediate gear 150b and the first introduction side gear 110a meshing with the second introduction side gear 110b are driven.
The second discharge side gear 120b meshing with the second intermediate gear 150c and the first discharge side gear 120a meshing with the second discharge side gear 120b are respectively driven.
As a result, the first introduction-side roller 11a, the cylindrical mold roller 10, and the first discharge-side roller 12a all rotate in the same direction, and cooperate with these rollers so as to cooperate with these rollers. The side roller 12b rotates in the reverse direction.
The stacked sheets s are introduced into the insole manufacturing apparatus 1 by the operation of these gears.

Further, the ultrasonic oscillation device is operated, and the horn 13 is oscillated by ultrasonic waves.

  The sheet compressed and introduced by the first sheet introduction side roller 11a and the second sheet introduction side roller 11b passes over the upper process side guide plate 14a, and the contact surface 13a of the horn 13 and the cylindrical mold roller 10 are in contact with each other. Pass between.

  The pressing portion 101 formed on the peripheral surface of the cylindrical mold roller 10 presses and holds the stacked sheets s with the contact surface 13 a of the horn 13, and the lower sheet 40 is oscillated by the oscillation of the horn 13. Is melted, and the upper sheet 30 and the lower sheet 40 are welded together to form an emboss (see FIG. 5).

Here, on the peripheral surfaces on the left and right end sides of the cylindrical mold roller 10, as shown in FIG. 3, a guide pressing portion 103 for preventing sheet wrinkles having an oblique line contour is provided so as to spread the sheet slightly outward. They are arranged in two rows on the left and right.
That is, the guide pressing portion 103 is formed with a convex portion 103 a so as to be inclined with respect to the rotation direction of the mold roller 10. Further, the end portion (front end 103b) that is rearward in the rotation direction of the convex portion 103a is formed closer to the center in the width direction of the cylindrical mold roller 10 than the end portion (rear end 103c ) that is the front side in the rotation direction. It is. With this configuration, the clamping position between the guide pressing portion 103 and the horn 13 gradually moves outward in the width direction as the cylindrical mold roller 10 rotates. Therefore, the nipped sheet is moved in the same direction as the nipping position moves outward in the width direction, and the entire sheet is pushed outward.

  By providing the sheet pressing preventing portion 103 for preventing sheet wrinkles in the left and right rows as a range of wrinkle prevention in a portion excluding the insole forming portion, it is thick like the bore fabric shown in this embodiment. Even an insole made of three sheets or more can be securely fixed and transported.

  Further, the cutting blade portion 102 formed on the peripheral surface of the cylindrical die roller 10 is melted and cut while firmly sandwiching the sheet s laminated with the horn 13 in the oscillation state, and is commercialized from the laminated sheet s. Make the insole separable.

  The portion of the laminated sheet s that is not pressed or cut by the cutting means and the pressing portion 101 is hardly affected by ultrasonic waves because there is no protrusion at the corresponding position on the peripheral surface of the cylindrical mold roller 10, Properties such as flexibility of the sheet suitable for the insole are retained.

The laminated sheet s in which the insole is separable is advanced on the lower process side guide plate 14b as a third process in the present invention, and is sandwiched between the first discharge side roller 12a and the second discharge side roller 12b. After being pressed, it is discharged to the lower process side.
On the lower process side, the commercial insole is separated from the stacked sheets s and discharged. The separation piece 52 separated from the sheet s can be easily recovered and discarded by dropping it into a separation piece disposal box (not shown) prepared below.

The present invention is not limited to the above embodiment. For example, the plurality of sheets for constituting the insole may be three or more sheets, the upper sheet 30, the lower sheet 40, and the first intermediate sheet (or second and subsequent sheets) interposed therebetween. In this case, the intermediate sheets may be stacked as a roll and introduced into the sheet introduction side roller. For example, the upper sheet 30 may be a pile fabric, the lower sheet 40 may be a non-woven fabric, and the first intermediate sheet may be a sheet woven with polyester yarn.
In addition, like a general insole, the sheet can be made of a material that can ensure the breathability of the insole. For example, in addition to a formed sheet, a knitted sheet, a foamed sheet having open cells, and the like are used. You can also. The layout of the sheet supply line can be appropriately changed depending on the number of sheets to be stacked.

  In the above embodiments, polyester sheets are laminated and melted together. However, the present invention is not limited to this. For example, a sheath core formed by winding a sheath material having a low melting point on a core material. The use of sheets having monofilament yarns and melting of the low melting point sheath component can also be used for welding the sheets together. Further, for example, a hot melt sheet such as a hot melt adhesive can be used as one of the sheets constituting the insole.

Further, in the above embodiment, the guide pressing portion 103 formed on the peripheral surface of the cylindrical die roller 10 has a front end 103b of the convex portion 103a that is inclined with respect to the rotation direction, and the center in the width direction of the roller rather than the rear end 103c. However, the present invention is not limited to the above-described embodiment, and the front end 103b and the rear end 103c are arranged at an oblique position in addition to the case where the oblique is a straight line. Meaning that it may be curved.

Moreover, if the said structure is provided, it arrange | positions left-right symmetrically so that the distance between the rear ends 103c may become larger than the distance between the front ends 103b , for example, and the sheet may be extended to the left and right sides.

DESCRIPTION OF SYMBOLS 1 Insole manufacturing apparatus 10 Cylindrical mold roller 100 Mold gear 101 Press means (press part)
102 Cutting means (cutting blade part)
103 Guide pressing part
103a Convex
103b front end
103c Rear end 11a First sheet introduction side roller 110a First introduction side gear 11b Second sheet introduction side roller 110b Second introduction side gear 12a First discharge side roller 120a First discharge side gear 12b Second discharge side roller 120b Second Discharge side gear 13 Horn (Ultrasonic oscillator)
13a Contact surface 14a Upper process side guide plate 14b Lower process side guide plate 15 Gear storage 150a Drive gear 150b First intermediate gear 150c Second intermediate gear 150d Power transmission belt (or chain)
16 Guide Block 16a Female Screw 17a Guide Frame 17b Handle Holding Member 18 Handle 180 Handle Shaft 19 Ultrasonic Oscillator 2 Carry-on Conveyor 3 Upper Sheet Roll 30 Upper Sheet 4 Lower Sheet Roll 40 Lower Sheet 5 Insole 50 Cutting Line 51 Embossed 52 Separation pieces s Stacked sheets

Claims (7)

A cylindrical mold roller having a pressing means and a cutting means for the laminated sheets on the circumferential surface, and an ultrasonic oscillator sandwich the laminated sheets, and weld and cut a part of the sheets, A method of manufacturing an insole that is formed,
The cylindrical die roller is provided with a plurality of guide pressing portions that extend the plurality of stacked sheets in the width direction at least in a plurality of positions on the left and right in the width direction on the circumferential surface,
The guide pressing portion has a convex portion that intersects the rotation direction and has an end that is rearward in the rotation direction and is located closer to the center in the width direction of the cylindrical mold roller than the end that is the front. Manufacturing method of insole. A first step of polymerizing and laminating a plurality of sheets; a second step of simultaneously welding and cutting the laminated sheets by the cylindrical die roller and the ultrasonic wave oscillating unit; and a first step of discharging the obtained insole With three steps,
The cutting means in the cylindrical mold roller has a protruding amount from the roller peripheral surface larger than the protruding amount of the pressing means, and the ultrasonic oscillator is a horn having a contact surface,
In the second step, the convex portion presses the laminated sheets on the contact surface of the ultrasonic horn, and the laminated sheets are welded to each other. The method of manufacturing an insole according to claim 1, wherein a cutting blade portion as the cutting means cuts the stacked sheets on a contact surface of a horn. The first step has a pair of sheet introduction side rollers for laminating a plurality of sheets, and the third step has a pair of discharge side rollers for discharging the insole,
The second step has a guide portion that guides the bottom side of the stacked sheets,
The at least one sheet introduction side roller of the pair of sheet introduction side rollers in the first step can adjust a distance from the other sheet introduction side roller in the first step. Manufacturing method of insole.   4. The distance between the at least one sheet discharge side roller of the pair of sheet discharge side rollers in the third step and the other sheet discharge side roller in the third step can be adjusted. Insole manufacturing method.   At least one of the laminated sheets is a sheet containing a sheath-core monofilament thread formed by coating the surface of a monofilament with a low-melting polymer, and the low-melting polymer is welded using ultrasonic means. A method for producing an insole according to claim 1, 2, 3, or 4. A pair of sheet introduction side rollers for introducing a plurality of sheets in a superposed manner, a cylindrical mold roller and an ultrasonic oscillator provided with a pressing means and a cutting means on the peripheral surface for melting and cutting the laminated sheets And a pair of discharge-side rollers for discharging the insole from the upper process to the lower process in sequence,
A guide portion is provided between the sheet introduction side roller and the discharge side roller to guide the bottom side of the stacked sheets,
Cylindrical mold roller, at least a plurality of the left and right in the width direction on the peripheral surface, a guide pressing portion that spreads a plurality of stacked sheets in the width direction is arranged in a row,
The guide pressing part has a convex part that is arranged closer to the center in the width direction of the cylindrical mold roller than an end part that intersects the rotation direction and is rearward in the rotation direction. Insole manufacturing equipment. A sheet introduction side gear is provided at one end of the pair of sheet introduction side rollers, a mold gear is provided at one end of the cylindrical mold roller, and a discharge side gear is provided at one end of the pair of discharge side rollers,
A driving gear for transmitting power from a driving source is provided, and power is transmitted directly or indirectly from the driving gear to each sheet introduction side gear, mold gear, and each discharge side gear; 7. The insole manufacturing apparatus according to claim 6, wherein the cylindrical mold roller and the discharge side roller are operated.

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