JP6664239B2 - Filament three-dimensional combined body manufacturing apparatus and filament three-dimensional combined body - Google Patents

Description

  The present invention relates to a three-dimensional filament assembly and an apparatus for producing the same.

  As a cushion material used for a mattress, a pillow, and the like, a filament three-dimensional composite obtained by partially fusing a plurality of thermoplastic resin fibers (molten filaments) in a molten state has recently attracted attention.

  For example, in Patent Literature 1, when fusion filaments made of a thermoplastic resin in a molten state extruded from a plurality of nozzles are three-dimensionally fusion-bonded to each other, the filaments are inclined downward toward a central portion. A plurality of molten filaments are dropped on a pair of plate members arranged with a gap. By doing so, the filament three-dimensionally combined body has smooth surfaces at both ends in the thickness direction of the mattress.

JP 2013-57158 A

  However, in the mattress manufactured in Patent Literature 1, the filament density near the surfaces at both ends in the thickness direction of the mattress increases, so that a hard surface layer is formed on the mattress surface. Therefore, when the user sleeps as shown in FIG. 13, the mattress is deformed into a V-shape with the ground point of the user's body at the top. Therefore, there is a problem that a soft sleeping comfort that fits the body shape is impaired.

  On the other hand, in order to suppress the hardening of the surface layer of the mattress, by increasing the pitch of the nozzles that discharge the filaments to the surface layer and reducing the filament density near the surface of the mattress, the number of voids in the surface layer increases, There was a problem that the surface smoothness was impaired, for example, a relatively large hole of 2 cm was formed.

  The present invention has been made in view of the above-mentioned problems, and an apparatus for manufacturing a three-dimensional filament assembly capable of reducing the surface hardness without impairing the repulsive force and the surface smoothness of the filament three-dimensional assembly, and It is an object to provide a filament three-dimensional assembly obtained.

  In order to achieve the above object, an apparatus for manufacturing a three-dimensionally combined filament according to one aspect of the present invention includes a molten filament supply device that discharges a plurality of molten filaments from a nozzle portion, and a filament 3 in which the molten filaments are fusion bonded. A three-dimensional combined body forming apparatus for forming a three-dimensional combined body, wherein the nozzle unit is provided with a nozzle group including a first nozzle and a second nozzle having an opening cross-sectional area smaller than the first nozzle. In a predetermined direction on the cross section of the nozzle section that intersects with the discharge direction of the molten filament, the first nozzles are provided more in the center than the ends of the cross section, and the second nozzles are provided in It is configured to be provided at a large amount at the end.

  According to this configuration, the relatively thick molten filament is discharged from the first nozzle, and the relatively thin molten filament is discharged from the second nozzle. Then, when the fused filaments are fused and bonded to form a filament three-dimensional combined body, in a central region in a predetermined direction (for example, a thickness direction) on a cross section that intersects the forming direction of the filament three-dimensional combined body. However, the number of relatively thick molten filaments is larger. Further, in the region of the end portion (that is, the surface layer) in the predetermined direction, the number of relatively thin filaments is larger.

  Therefore, it is possible to suppress a decrease in the repulsive force of the filament three-dimensionally combined body, and it is possible to suppress the surface layer from becoming excessively hard without lowering the surface smoothness. Therefore, the surface hardness can be reduced without impairing the repulsion force and surface smoothness of the three-dimensionally combined filament.

  In the above-described apparatus for manufacturing a three-dimensionally combined filament, the nozzle group may be provided in a region having a longitudinal direction and a lateral direction on the cross section, and the predetermined direction may be the lateral direction. .

  According to this configuration, it is possible to form a filament three-dimensional combined body having a cross section orthogonal to the discharge direction of the molten filament having a shape having a longitudinal direction and a transverse direction. Furthermore, many first nozzles are provided at the center in the short direction of the region where the nozzle group is provided, and many second nozzles are provided at the ends in the short direction. Therefore, in the central part in the thickness direction of the three-dimensionally combined filament, the number of relatively thick molten filaments is larger. At the end (that is, the surface layer) in the thickness direction, the number of relatively thin filaments is larger. Therefore, the surface hardness can be reduced without impairing the repulsive force and the surface smoothness, particularly in the thickness direction of the filament three-dimensional combined body.

  In the above three-dimensional filament manufacturing apparatus, the opening shape of the first nozzle is a shape having a major axis and a minor axis on the cross section, and the minor axis is the opening of the first nozzle in the lateral direction. The configuration may be the inner diameter of the shape.

  According to this configuration, the cross section of the relatively thick filament discharged from the first nozzle can be formed into a flat shape having a major axis and a minor axis. Further, a relatively thick flat filament is likely to wave in a predetermined direction (for example, a thickness direction) on a cross section of the three-dimensionally combined filament when discharged. Therefore, the repulsive force (hardness) of the three-dimensionally combined filament in a predetermined direction can be easily stabilized.

  The above-described apparatus for manufacturing a three-dimensionally combined filament may have a configuration in which the ratio of the major axis to the minor axis of the opening shape of the first nozzle is 2 or more and 10 or less.

  According to this configuration, the degree of freedom in the wave direction (amplitude direction) of the relatively thick flat filament discharged from the first nozzle can be adjusted appropriately. That is, it is possible to prevent the wave direction from being excessively varied in the direction other than the predetermined direction on the cross section (for example, the short direction of the region on the cross section) or being too uniform in the short direction. Accordingly, it is possible to suppress a decrease in bonding (linking) with another filament adjacent in a direction other than the predetermined direction, and to suppress a local decrease in repulsion.

  In the above-described filament three-dimensional combined body manufacturing apparatus, on the cross section, the opening shape of the second nozzle is a shape having a major axis and a minor axis, and the minor axis is an opening shape of the second nozzle in the longitudinal direction. The inner diameter may be the same as the inner diameter.

  According to this configuration, the cross section of the relatively thin filament discharged from the second nozzle can be formed into a flat shape having a major axis and a minor axis. Furthermore, the relatively thin flat filament is likely to wave in the longitudinal direction of the region where the nozzle group is provided (for example, in the width direction of the filament three-dimensional combined body) when being discharged. Therefore, the bonding (linking) with other filaments (particularly, relatively thick filaments) can be promoted, and the bonding strength between the filaments can be improved.

  In the above-described filament three-dimensional combined body manufacturing apparatus, the nozzle group further includes a third nozzle having an opening cross-sectional area smaller than that of the first nozzle, and in the predetermined direction, the third nozzle is located at a central portion of the cross section. A configuration may be provided.

  According to this configuration, a relatively thin filament is also present in a central region in a predetermined direction (for example, a thickness direction) on a cross section that intersects the formation direction of the filament three-dimensional combined body, and a relatively thick filament is formed. Can be combined. Therefore, the bonding point density (linking density) per unit volume in the central portion can be increased, and a stable repulsive force can be obtained. Therefore, for example, it is possible to reduce a local decrease in the repulsive force that occurs at a portion where the coupling point density is small.

  In the above-described apparatus for manufacturing a three-dimensionally combined filament, in the cross section, the opening shape of the third nozzle is a shape having a major axis and a minor axis, and the minor axis is an opening shape of the third nozzle in the longitudinal direction. The inner diameter may be the same as the inner diameter.

  According to this configuration, a relatively thin flat filament can be discharged from the third nozzle. Further, by the wave of the flat filaments, the bonding (linking) with other filaments (particularly, relatively thick filaments) is promoted, and the bonding strength between the filaments can be improved.

  In the above-described filament three-dimensionally bonded body manufacturing apparatus, in the predetermined direction, the first nozzles are provided more at the center than the both ends of the cross section, and the second nozzles are provided more at the both ends than the center. A configuration may be provided.

  According to this configuration, it is possible to reduce the hardness of both surfaces by increasing the number of relatively thin filaments at both ends (both front and rear sides) in the predetermined direction.

  In order to achieve the above object, a three-dimensional filament composite according to one aspect of the present invention is a three-dimensional filament composite in which a plurality of filaments are fusion-bonded three-dimensionally. A filament in a thickness direction of the three-dimensionally combined filament, wherein a volume ratio of the second filament to the first filament at an end portion is a central portion. It is configured to be larger than the volume ratio at.

  According to this configuration, in the central region in the thickness direction of the filament three-dimensional combined body, the number of the relatively thick molten filaments increases, and in the region of the end portion (namely, the surface layer) in the thickness direction, the relative thickness increases. Thinner filaments are more common. Therefore, it is possible to suppress a decrease in the repulsive force of the filament three-dimensionally combined body, and it is possible to suppress the surface layer from becoming excessively hard without lowering the surface smoothness. That is, the surface hardness can be reduced without impairing the repulsive force and surface smoothness of the three-dimensionally combined filament.

  Further, when the filament three-dimensional combined body is used for a mattress, for example, it is possible to obtain a resilient force that easily rolls over and a soft sleeping comfort that fits the shape of the body.

  ADVANTAGE OF THE INVENTION According to this invention, the hardness of a surface can be reduced, without impairing the repulsion and the smoothness of the surface of the three-dimensionally combined filament.

It is a conceptual diagram which shows an example of a filament three-dimensional assembly manufacturing apparatus. FIG. 2 is an A-A ′ cross-sectional arrow of the filament three-dimensional assembly manufacturing apparatus shown in FIG. 1. It is a block diagram which shows the example of a structure of the filament three-dimensional-combined body manufacturing apparatus shown in FIG. It is an enlarged view of a pair of slat conveyors. It is a horizontal sectional view about a nozzle part concerning a 1st embodiment. It is an example of the shape of the horizontal section of the opening of the 1st nozzle concerning a 1st embodiment. It is a conceptual diagram at the time of using a filament three-dimensional assembly as a mattress. It is a horizontal sectional view about a nozzle part concerning a 2nd embodiment. It is an example of the shape of the horizontal section of the opening of the 1st nozzle concerning a 2nd embodiment. It is a horizontal sectional view about a nozzle part concerning a 3rd embodiment. It is a conceptual diagram which shows the preferential vibration direction (wave direction) of the molten filament discharged | emitted from the nozzle group which consists of a flat-shaped nozzle. It is a conceptual diagram which shows the wave direction of the thick filament and the thin filament in a filament three-dimensional combined body. It is a conceptual diagram at the time of using the conventional filament three-dimensional combined body as a mattress.

  An embodiment of the present invention will be described below with reference to the drawings. In the following description, the unit of the length or the area may be indicated with [] like [mm] in consideration of legibility.

<First embodiment>
FIG. 1 is a configuration diagram illustrating an example of a filament three-dimensional combined body manufacturing apparatus 1. FIG. 2 is a sectional view taken along the line AA ′ of the filament three-dimensionally bonded body manufacturing apparatus 1 shown in FIG. FIG. 3 is a block diagram illustrating a configuration example of the filament three-dimensionally bonded body manufacturing apparatus 1 illustrated in FIG. 1.

  In FIG. 1, a filament three-dimensional combined body manufacturing apparatus 1 is an apparatus for manufacturing a filament three-dimensional combined body 3 made of a thermoplastic resin fiber having a three-dimensional network structure, and includes an extruder 10 and a three-dimensional combined body. The apparatus includes a forming device 20 and a controller (not shown) that controls each component of the filament three-dimensionally bonded body manufacturing device 1. Hereinafter, the thermoplastic resin fiber is referred to as a filament 2, and the filament three-dimensional combined body 3 is referred to as an FTS (Filament-linked Three-dimensional Structure) 3. Further, the filament three-dimensional combined body manufacturing apparatus 1 is referred to as an FTS manufacturing apparatus 1.

  The extruder 10 is an example of a molten filament supply device that forms a filament 2 in a molten state and discharges (supplies) the filament 2 to a three-dimensional combined body forming device 20. The extruder 10 includes an extruder 11 which is a pressurizing and melting unit provided with a hopper 13 for inputting a material, and a die 12 and the like connected to the extruder 11 and having a nozzle unit 17. From 17, the molten filament 2 is sent out. Hereinafter, the filament 2 in a molten state is referred to as a molten filament 2.

  The hopper 13 is a material input section for inputting a thermoplastic resin as a material of the filament 2 into the extruder 10. As the thermoplastic resin, for example, a polyolefin resin such as polyethylene and polypropylene, a polyester resin such as polyethylene terephthalate, a polyamide such as nylon 66, polyvinyl chloride, and polystyrene can be used. Alternatively, a copolymer or elastomer obtained by copolymerizing these resins as a base may be used, or these resins may be blended and used.

  The extruder 11 is a pressure melting unit that melts the thermoplastic resin while pressing it. Inside the extruder 11, a cylinder 11a is formed. A screw 14 rotated by a screw motor 15 is inserted into the cylinder 11a. A screw heater 16 (16a, 16b, 16c) is provided on the outer periphery of the cylinder 11a. The screw 14 is a pressurizing and conveying member that presses the thermoplastic resin that is heated and melted by the screw heater 16 and conveys the thermoplastic resin to the die 12 from the filament discharge unit 11b. The screw heater 16 is a heating unit that heats the thermoplastic resin in the cylinder 11a.

  The die 12 is a filament sending section that sends out the thermoplastic resin in a molten state transported from the extruder 11 into fibrous molten filaments 2. Inside the die 12, a die conduction channel 12a is formed. The die heater 18 is a heating unit that heats the molten filament 2 passing through the die conduction channel 12a. A plurality of openings (a nozzle group 17a described later) having different opening cross-sectional areas are formed in the nozzle portion 17. The nozzle unit 17 sends out the molten filament 2 from the nozzle group 17a to the outside to form a plurality of fibrous molten filaments 2.

  A temperature sensor 19 (19a, 19b, 19c) for measuring the temperature of the molten filament 2 is provided near the die heater 18, and a temperature sensor (not shown) is also provided near the screw heater 16. The outputs of the screw heater 16 and the die heater 18 are controlled based on the measurement results of the temperature by these temperature sensors.

  The extruder 10 melts the thermoplastic resin supplied from the hopper 13 in the cylinder 11a by the screw 14, the screw heater 16, the die heater 18, and the like. Thereafter, the extruder 10 derives a plurality of molten filaments 2 from a nozzle group 17a formed of a plurality of types of circular nozzles formed in the nozzle portion 17 via a die guide channel 12a inside the die 12. The further configuration of the nozzle unit 17 will be described later in detail.

  Next, the three-dimensional combined body forming apparatus 20 forms the FTS 3 having a three-dimensional network structure by fusion bonding and cooling and solidifying the plurality of molten filaments 2. The three-dimensional combined body forming apparatus 20 includes receiving plates 21a and 21b, and a cooler 22 including a water tank 23 for storing cooling water 22a.

  The receiving plates 21a and 21b are arranged opposite to each other in an inverted C-shape when viewed in the same direction as the direction in which FIG. 1 is viewed, and are examples of a filament connecting portion that fuses and bonds the molten filaments 2 to each other. The receiving plates 21a and 21b receive the plurality of fibrous molten filaments 2 sent out from the die 12 thereunder, and temporarily retain the molten filaments 2. The receiving plates 21a and 21b promote the fusion bonding of the retained molten filaments 2 by the buoyancy of the cooling water 22a in the water tank 23. That is, the molten filament 2 receives the buoyancy of the cooling water 22a in the water tank 23 inside the receiving plates 21a and 21b, and the transport speed (take-up speed) of the slat conveyor 24 described later is lower than the falling speed of the molten filament 2. Since they are set, they stay inside the receiving plates 21a and 21b. At this time, the plurality of molten filaments 2 are partially fusion-bonded and three-dimensionally bonded to form the FTS 3.

  Note that a cooling water supply / water absorbing device (not shown) that supplies cooling water to the entire surface of the receiving plates 21a and 21b may be provided above the receiving plates 21a and 21b. By suppressing or preventing the temperature rise of the receiving plates 21a and 21b by the supply of the cooling water, the fusion filament 2 can be prevented from being fused to the receiving plates 21a and 21b.

  The cooler 22 is an example of a filament cooling unit, and cools and solidifies the fusion-bonded molten filament 2. The cooler 22 has a water tank 23 storing cooling water 22a, a pair of slat conveyors 24 (24a, 24b), a plurality of transport rollers 25a to 25g, and a transport motor 26.

  The pair of slat conveyors 24 (24a, 24b) and the plurality of transport rollers 25a to 25g are a transport device that transports the FTS3. The pair of slat conveyors 24 are provided below the receiving plates 21a and 21b in the vertical direction, and move downward while cooling the mesh-like molten filaments 2 that have undergone three-dimensional fusion bonding with the cooling water 22a, The solidified FTS 3 is transported. The conveying speed of the slat conveyor 24 is closely related to the filament density. That is, depending on the cooling speed of the molten filament 2, the filament density decreases as the transport speed increases, and the filament density increases as the transport speed decreases. The transport rollers 25a to 25g are arranged at a stage subsequent to the pair of slat conveyors 24, and transport the FTS 3 having passed through the slat conveyor 24 to the outside of the water tank 23. In the present embodiment, the slat conveyor 24 is used as an example of the endless conveyor, but there is no particular limitation as long as it is a transport device. For example, instead of the slat conveyor 24, an endless conveyor or the like in which an endless wire mesh (not shown) is fixed to the outer periphery of the plurality of guide plates 34 may be used.

  The transport motor 26 is a drive unit of a transport member that transports the FTS 3, and drives the pair of slat conveyors 24 and the plurality of transport rollers 25 (25 a to 25 g) at the same speed via gears (not shown) to drive the FTS 3 into the water tank 23. Transport outside.

  Next, a more detailed configuration of the slat conveyor 24 will be described. FIG. 4 is an enlarged view of the pair of slat conveyors 24. In FIG. 4, the pair of slat conveyors 24 includes a first slat conveyor 24a and a second slat conveyor 24b which are arranged in parallel at a predetermined interval, and are provided such that the transport direction of the FTS3 is vertically downward. ing. Hereinafter, the configuration of the first slat conveyor 24a will be mainly described. Since the configuration of the second slat conveyor 24b is the same as that of the first slat conveyor 24a, its description is omitted.

  The first slat conveyor 24a has a driven gear 31, a drive gear 32, an endless guide plate holding member 33, and a plurality of guide plates. The guide plate holding member 33 is a chain stretched by the driven gear 31 and the drive gear 32, and holds a plurality of guide plates. The driven gear 31 and the driving gear 32 are rotationally driven by the transport motor 26 (see FIG. 3), and drive the guide plate holding member 33. That is, the plurality of guide plates 34 are driven along the outer periphery of the slat conveyor 24 by the drive member including the driven gear 31, the drive gear 32, and the guide plate holding member 33.

  Each of the plurality of guide plates 34 is a plate-shaped transport member that rotates along the outer periphery of the first slat conveyor 24a together with the guide plate holding member 33, and moves the FTS 3 that is in contact with the surface thereof vertically downward.

  Next, a specific configuration of the nozzle unit 17 will be described. FIG. 5 is a diagram illustrating a main part of a discharge portion of the molten filament 2 of the nozzle unit 17 according to the first embodiment. FIG. 5A is a horizontal sectional view of the nozzle unit 17 according to the first embodiment, and FIG. 5B is a horizontal sectional view of the nozzle unit 117 according to a modification of the first embodiment. In FIG. 5, the shape of the nozzle forming area where the nozzle group 17a is provided is rectangular on a horizontal cross section (a cross section orthogonal to the discharge direction of the filament 2) of the discharge portion of the nozzle portion 17. It is not limited to the illustration. The shape can be adopted according to the shape of the horizontal cross section (cross section orthogonal to the transport direction) of the FTS 3 as long as it has a longitudinal direction and a lateral direction. This is the same in other embodiments (see FIGS. 8 and 10 described later).

  In FIG. 5A, the nozzle group 17a formed at the discharge portion of the molten filament 2 includes a plurality of first nozzles 17b and a plurality of second nozzles 17c. The sectional area (opening sectional area) of the opening of the first nozzle 17b is larger than the sectional area of the opening of the second nozzle 17c. The formation positions of the plurality of first nozzles 17b are gathered in the vicinity of the center (region of the center) in the short direction of the nozzle formation region on the horizontal cross section of the nozzle portion 17. The formation positions of the plurality of second nozzles 17c are gathered near the ends on both sides in the lateral direction of the nozzle formation region on the horizontal cross section of the nozzle portion 17 (end region).

In the present embodiment, the inner diameter of the first nozzle 17b is 1 [mm], and the opening cross-sectional area is 0.79 [mm ² ]. The shortest distance (distance between nozzles) between adjacent first nozzles 17b is set to 10 [mm]. The inner diameter of the second nozzle 17c is 0.6 [mm], and the cross-sectional area of the opening is 0.28 [mm ² ]. The distance between the adjacent second nozzles 17c and the shortest distance between the first nozzle 17b and the second nozzle 17c are set to 6 [mm]. Note that the shortest distance between the nozzles is not limited to the above example, and can be appropriately adjusted based on the specifications of the resilience and the smoothness of the FTS 3.

  Further, the ratio of the opening cross-sectional area of the second nozzle 17c to the first nozzle 17b (second nozzle opening cross-sectional area / first nozzle opening cross-sectional area) is not particularly limited. However, if the ratio is too small, it is difficult to obtain the effects of the present invention. If the ratio is too large, it is difficult to stabilize the discharge rate per unit time of both the molten filaments 2 discharged from the first nozzle 17b and the second nozzle 17c. Therefore, the ratio of the opening cross-sectional areas is preferably 1.5 or more and 15 or less, and more preferably 2 or more and 10 or less.

  A relatively thick molten filament (hereinafter, sometimes referred to as “molten filament 2a”) discharged from the first nozzle 17b tends to gather near the center of the FTS 3 in the thickness direction. Relatively thin molten filaments (hereinafter, sometimes referred to as “molten filaments 2b”) discharged from the second nozzle 17c easily gather near both ends (surface layer) in the thickness direction of the FTS3. As a result, the vicinity of the end of the FTS 3 in the thickness direction (hard surface layer) is compressed to increase the filament density, but the composition ratio of the relatively thin filament 2b is increased. Therefore, it is possible to suppress the hard surface layer from becoming excessively hard. On the other hand, in the vicinity of the central portion in the thickness direction of the FTS 3, the composition ratio of the relatively thick filament 2a increases, so that a decrease in the repulsive force can be suppressed.

  The nozzle group 17 of the present embodiment can adjust the diameter and the cross-sectional area of each filament 2 in the FTS 3 to be formed by adjusting the inner diameter and the cross-sectional area of the first nozzle 17b and the second nozzle 17c. . However, depending on the modulus of elasticity of the thermoplastic resin and the manufacturing conditions (such as the distance from the lower end of the nozzle portion 17 to the water surface), the relative thickness and cross-sectional area of the nozzles 17b and 17c do not change even if the relationship does not change. The inner diameter and the cross-sectional area may not completely match the thickness and the cross-sectional area of the filament 2. Therefore, by grasping in advance the relational expression between the inner diameter and the cross-sectional area of each of the nozzles 17b and 17c and the thickness and the cross-sectional area of the filament 2, each of the nozzles 17a and 17c can be adjusted to have the desired thickness and the cross-sectional area of the filament It is desirable to finely adjust the inner diameter and cross-sectional area of 17b and 17c.

(Modification of Nozzle 17)
In FIG. 5B, the nozzle group 117a formed at the discharge portion of the molten filament 2 includes a plurality of first nozzles 117b, second nozzles 117c, and third nozzles 117ca. The cross-sectional area (opening cross-sectional area) of each opening of the second nozzle 117c and the third nozzle 117ca is smaller than the opening cross-sectional area of the first nozzle 117b. The nozzle unit 117 in FIG. 5B has the same configuration as the nozzle unit 17 in FIG. 5A except that a third nozzle 117ca is formed between the adjacent first nozzles 117b. .

  In the nozzle part 117, the relatively thin molten filament 2c discharged from the third nozzle 117ca between the adjacent first nozzles 117b is combined with the relatively thick molten filament 2a discharged from the first nozzle 117b. In addition, the bonding point density per unit volume (linking density) can be increased. Accordingly, since a local decrease in the repulsive force generated at a portion having a low coupling point density can be reduced, the FTS 3 can obtain a stable repulsive force.

  In the present embodiment, the first nozzles 17b and 117b are not formed at the ends in the short direction of the nozzle forming region on the horizontal cross section of the nozzle portions 17 and 117, but are not limited to this example. A smaller number of first nozzles 17b, 117b than the central part in the hand direction may be formed at the end part in the short direction. However, as the number of the first nozzles 17b and 117b formed at the ends in the short direction increases, the number of the relatively thick filaments 2a existing in the surface layer of the FTS3 also increases. The layer tends to be hard. Therefore, it is preferable to reduce the number of the first nozzles 17b and 117b formed at the ends in the short direction according to the hardness of the surface layer of the FTS3. This is the same in other embodiments.

  Further, in the present embodiment, a solid molten filament 2 having a horizontal horizontal section is formed by using the nozzle groups 17a and 117a having a circular horizontal cross section at the opening (see FIG. 6A). . The shape of the horizontal section of the opening portion is not limited to this example, and may be a polygonal shape such as a triangle, a quadrangle (see FIG. 6B), and a hexagon (see FIG. 6C). When the molten filaments 2 having a polygonal cross section and a solid shape are formed using the polygonal nozzle groups 17a and 117a, the molten filaments 2 are brought into surface contact with each other to increase the contact area of the coupling portion, and the bonding strength thereof Can be improved.

  Alternatively, the shape of the horizontal cross section of the opening portion of the nozzle group 17a, 117a may be a shape capable of forming the molten filament 2 having a hollow horizontal cross section as shown in, for example, FIGS. Good. The nozzle groups 17a and 117a having a horizontal cross section as shown in FIGS. 6 (d) to 6 (f) are arranged such that the central part thereof is connected to the nozzle parts 17 and 117 main body at any part (for example, upstream part) in the discharge direction. It can be realized by connecting. The outer peripheral shape and the inner peripheral shape of the horizontal section of the opening may be the same as shown in FIGS. 6D to 6H or may be different. In the molten filament 2 having a hollow cross section, the outer diameter has a greater effect on smoothness and repulsion than the inner diameter. Therefore, when calculating these opening cross-sectional areas, it is desirable to calculate it assuming that there is no hollow portion in the molten filament 2.

  The FTS 3 described above can be applied to, for example, a mattress. FIG. 7 is a conceptual diagram when FTS3 is used as a mattress. In the FTS 3 obtained by the above-described FTS manufacturing apparatus 1, the volume ratio of the relatively thin filament 2b to the relatively thick filament 2a is larger at both ends than the center in the thickness direction of the FTS 3 (that is, the surface layer portion of the mattress). ). Therefore, it is possible to suppress the surface layer of the FTS 3 from becoming excessively hard without impairing the resilience of the FTS 3. As a result, when the FTS 3 is applied to a mattress, it is possible to obtain a resilient force that easily rolls over and a soft sleeping comfort that fits the shape of the body.

  As described above, the FTS manufacturing apparatus 1 according to the present embodiment includes the extruder 10 (molten filament supply device) that discharges the plurality of molten filaments 2 from the nozzle portions 17 and 117, and the FTS ( And a three-dimensional combined body forming apparatus 20 for forming the three-dimensional combined filaments 3). The nozzle portions 17 and 117 are provided with nozzle groups 17a and 117a including first nozzles 17b and 117b and second nozzles 17c and 117c having smaller opening cross-sectional areas than the first nozzles 17b and 117b. In a predetermined direction on the cross section of the nozzle portions 17, 117 crossing the discharge direction of the molten filament 2, the first nozzles 17b, 117b are provided more in a central region than in an end region of the cross section, The second nozzles 17c and 117c are provided more in an end region than in a central region of the cross section.

  In this case, the relatively thick molten filament 2a is discharged from the first nozzles 17b and 117b, and the relatively thin molten filament 2b is discharged from the second nozzles 17c and 117c. When the fused filaments 2 are fusion bonded to each other to form the FTS 3, a relatively thick molten filament 2 a is formed at a central portion in a predetermined direction (for example, a thickness direction) on a cross section that intersects the forming direction of the FTS 3. More. At the end (that is, the surface layer) in the predetermined direction, the number of the relatively thin filaments 2b is larger.

  Accordingly, a decrease in the resilience of the FTS 3 can be suppressed, and the surface layer can be prevented from being excessively hard without lowering the surface smoothness. Therefore, the surface hardness can be reduced without impairing the resilience of the FTS 3 and the surface smoothness. In the present embodiment, the number of the relatively thin filaments 2b is larger at both ends (both the front side and the back side) in the predetermined direction, and the hardness of both surfaces can be reduced. However, only one end (one of the front side and the back side) in the predetermined direction may be configured such that the number of the relatively thin filaments 2b increases.

  Further, in the FTS manufacturing apparatus 1, the nozzle groups 17a and 117a are provided in a nozzle forming region having a shape having a longitudinal direction and a transverse direction on the cross section, and the predetermined direction is a transverse direction of the nozzle forming region.

  By doing so, it is possible to form the FTS 3 in which the cross section orthogonal to the discharge direction of the molten filament 2 has a shape having a longitudinal direction and a transverse direction. Further, many first nozzles 17b and 117b are provided at the center in the short direction of the nozzle forming region where the nozzle groups 17a and 117a are provided, and many second nozzles 17c and 117c are provided at the ends in the short direction. . Therefore, in the central part in the thickness direction of the FTS 3, the number of the relatively thick molten filaments 2a is larger. At the end (that is, the surface layer) in the thickness direction, the number of relatively thin filaments 2b is larger. Therefore, particularly in the thickness direction of the FTS 3, the surface hardness can be reduced without impairing the repulsive force and the surface smoothness.

  In the FTS manufacturing apparatus 1, the nozzle group 117a further includes a third nozzle 117ca having an opening cross-sectional area smaller than that of the first nozzle 117b, and a cross section of the nozzle portion 117 crossing a discharge direction of the molten filament 2. In the upper predetermined direction, the third nozzle 117ca is provided at the center of the cross section.

  In this way, the relatively thin filament 2b can also be present at the center in a predetermined direction (for example, the thickness direction) on the cross section that intersects with the direction in which the FTS 3 is formed, and can be combined with the relatively thick filament 2a. Therefore, the bonding point density (linking density) per unit volume in the central portion can be increased, and a stable repulsive force can be obtained. Therefore, for example, it is possible to reduce a local decrease in the repulsive force that occurs at a portion where the coupling point density is small.

  In the FTS manufacturing apparatus 1, the first nozzles 17b and 117b are provided at the center in the short direction of the nozzle forming region on the cross section, and the second nozzles 17c and 117c are provided in the short direction. Direction end.

  In this way, in the short direction of the nozzle forming region where the nozzle groups 17a and 117a are provided, the relatively thick filament 2a is more in the center and the relatively thin filament 2b is more in the surface layer. An FTS 3 can be formed. Therefore, the effect of reducing the surface hardness can be further enhanced without impairing the resilience of the FTS 3 and the surface smoothness.

  The FTS 3 of the present embodiment is an FTS 3 in which a plurality of filaments 2 are fusion-bonded three-dimensionally. The filament 2 includes a first filament 2a and a second filament 2b that is thinner than the first filament 2a. The volume ratio of the second filament 2b to the first filament 2a at the end in the thickness direction of the FTS 3 is larger than the volume ratio at the center of the FTS 3 in the thickness direction.

  In this way, the number of relatively thick molten filaments 2a increases at the center of the FTS 3 in the thickness direction, and the number of relatively thin filaments 2b increases at the ends (that is, the surface layer) in the thickness direction. Become. Accordingly, a decrease in the resilience of the FTS 3 can be suppressed, and the surface layer can be prevented from being excessively hard without lowering the surface smoothness. That is, the surface hardness can be reduced without impairing the resilience of the FTS 3 and the surface smoothness.

  Further, when the FTS 3 is used for a mattress, for example, it is possible to obtain a resilient force that easily rolls over and a soft sleeping comfort that fits the shape of the body. In the present embodiment, the volume ratio at both ends (both front and rear sides) in the thickness direction of the FTS 3 is larger than the volume ratio at the center, and in the example used for the mattress, Even if you face up, you can get a soft sleep. However, only the volume ratio at one end (one of the front side and the back side) in the thickness direction of the FTS 3 may be larger than the volume ratio at the center.

<Second embodiment>
Next, a second embodiment will be described. Hereinafter, a configuration different from the first embodiment will be described. The same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof may be omitted.

  FIG. 8 is a diagram illustrating a main part of a discharge part of the molten filament 2 of the nozzle unit 17 according to the second embodiment. FIG. 8A is a horizontal sectional view illustrating an example of a nozzle unit 217 according to the second embodiment. FIG. 8B is a horizontal cross-sectional view illustrating an example of a nozzle unit 317 according to a first modification of the second embodiment. FIG. 8C is a horizontal cross-sectional view illustrating an example of a nozzle unit 417 according to a second modification of the second embodiment.

  In FIG. 8A, the nozzle group 217a formed at the discharge portion of the molten filament 2 includes a plurality of first nozzles 217b and a plurality of second nozzles 217c. The cross-sectional area (opening cross-sectional area) of the opening of the first nozzle 217b is larger than the cross-sectional area of the opening of the second nozzle 217c. The formation positions of the plurality of first nozzles 217b are gathered in the vicinity of the center in the short direction of the nozzle formation region on the horizontal cross section of the nozzle portion 217. The formation positions of the plurality of second nozzles 217c are collected near the ends on both sides in the short direction in the nozzle formation region on the horizontal cross section of the nozzle portion 217.

In the present embodiment, the shape of the horizontal cross section of the opening of the first nozzle 217b is substantially elliptical. The direction of the short diameter (shortest inner diameter) of the shape is the same as the short direction of the nozzle forming region on the horizontal cross section of the nozzle portion 217, and the direction of the long diameter (longest inner diameter) is on the horizontal cross section of the nozzle portion 217. This is the same as the longitudinal direction of the nozzle formation region. The opening cross-sectional area of the first nozzle 217b is 1.62 [mm ² ], and the distance between adjacent first nozzles 217b is set to 10 [mm]. The shape of the horizontal cross section of the opening of the second nozzle 217c is circular, and the inner diameter and the cross sectional area of the opening are 0.6 [mm] and 0.28 [mm ² ], respectively. The distance between adjacent second nozzles 217c and the shortest distance between the first nozzle 217b and the second nozzle 217c are each set to 6 [mm]. Note that the shortest distance between the nozzles is not limited to the above example, and can be appropriately adjusted based on the specifications of the resilience and the smoothness of the FTS 3.

  The ratio of the opening cross-sectional area of the second nozzle 217c to the first nozzle 217b is not particularly limited, but is preferably 1.5 to 15 and more preferably 2 to 10 as in the first embodiment. You.

  The relatively thick and flat cross section of the molten filament 2a discharged from the first nozzle 217b tends to gather near the center of the FTS 3 in the thickness direction. The relatively thin molten filament 2b discharged from the second nozzle 217c tends to gather near both ends (surface layer) in the thickness direction of the FTS3. As a result, the vicinity of the end of the FTS 3 in the thickness direction (hard surface layer) is compressed to increase the filament density, but the composition ratio of the relatively thin filament 2b is increased. Therefore, it is possible to suppress the hard surface layer from becoming excessively hard. On the other hand, near the center of the FTS 3 in the thickness direction, the composition ratio of the filament 2a having a relatively thick and flat cross section increases. Further, the filament 2a having a thick and flat cross section preferentially forms a wave in the thickness direction of the FTS 3 (that is, in the short direction in the nozzle forming region on the horizontal cross section of the nozzle portion 217). Therefore, it is possible to suppress a decrease in the repulsive force and obtain a stable repulsive force.

(First Modification of Nozzle 217)
In FIG. 8B, the nozzle group 317a formed at the discharge portion of the molten filament 2 includes a plurality of first nozzles 317b, second nozzles 317c, and third nozzles 317ca. The sectional area (opening sectional area) of each opening of the second nozzle 317c and the third nozzle 317ca is smaller than the opening sectional area of the first nozzle 317b. The nozzle unit 317 in FIG. 8B has the same configuration as the nozzle unit 217 in FIG. 8A except that a third nozzle 317ca is formed between adjacent first nozzles 317b. .

  In the nozzle part 317, the relatively thin molten filament 2c discharged from the third nozzle 317ca between the adjacent first nozzles 317b is combined with the relatively thick molten filament 2a discharged from the first nozzle 317b. In addition, the bonding point density per unit volume (linking density) can be increased. Accordingly, since a local decrease in the repulsive force generated at a portion having a low coupling point density can be reduced, the FTS 3 can obtain a stable repulsive force.

(Second Modified Example of Nozzle Unit 217)
The nozzle unit 417 in FIG. 8C has the same configuration as the nozzle unit 217 in FIG. 8A except that the shape of the horizontal cross section of the opening of the first nozzle 417b is different. The horizontal cross-sectional shape of the opening of the first nozzle 417b is rectangular. The short direction and the long direction of the shape are the same as the short direction and the long direction of the nozzle forming region on the horizontal cross section of the nozzle portion 417, respectively. The opening cross-sectional area of the first nozzle 417b is 1.80 [mm ² ], and the distance between adjacent first nozzles 417b is set to 10 [mm]. The distance between adjacent second nozzles 417c and the shortest distance between the first nozzle 417b and the second nozzle 417c are set to 6 [mm]. Note that the shortest distance between the nozzles is not limited to the above example, and can be appropriately adjusted based on the specifications of the resilience and smoothness of the FTS 3.

  The shape of the horizontal cross section of the opening of the first nozzles 217b, 317b, 417b is not limited to the example shown in FIG. The shapes of the first nozzles 217b, 317b, and 417b are substantially elliptical (see FIG. 9A) and rectangular (see FIG. 9B), as shown in FIGS. 9C and 9D. It may have a flat shape having a minor axis and a major axis. Further, the shape of the horizontal cross section of the opening portion of the first nozzles 217b, 317b, 417b may be a continuous circular shape in which circular openings continuously overlap in one direction as shown in FIGS. 9 (e) to 9 (g). Good. The molten filament 2 discharged from the continuous circular shape has a flat shape due to surface tension. In addition, since the shape of the horizontal cross section of the opening of the first nozzles 217b, 317b, 417b can be easily formed by, for example, drilling, the manufacturing cost of the nozzles 217, 317, 417 can be reduced.

  Further, the aspect ratio of the major axis (length in the longitudinal direction) to the minor axis (length in the lateral direction) of the flat shape as described above is preferably 2 or more and 10 or less, and more preferably 3 or more and 5 or less. Is done. If the aspect ratio is smaller than 2, the wave direction (amplitude direction) of the molten filament 2 varies. That is, since the degree of freedom in the wave direction increases, the ratio of the molten filament 2 that waves in the short direction decreases. Conversely, if the aspect ratio is greater than 10, the degree of freedom of the molten filament 2 in the wave direction is reduced, and the wave directions of the molten filament 2 are too aligned. That is, the ratio of the molten filament 2 waving in the short direction becomes very large, and the ratio of the molten filament 2 waving in other than the short direction decreases. Therefore, the bonding (linking) with the other filaments 2 adjacent in the direction other than the lateral direction is reduced, and a region where the repulsive force is locally reduced easily occurs.

  As described above, in the FTS manufacturing apparatus 1 of the present embodiment, the opening shapes of the first nozzles 217b, 317b, and 417b have a major axis and a minor axis on the cross section. The minor diameter is the inner diameter of the opening shape of the first nozzles 217b, 317b, 417b in the lateral direction of the region on the cross section.

  In this case, the cross section of the relatively thick filament 2a discharged from the first nozzles 217b, 317b, 417b can be formed into a flat shape having a major axis and a minor axis. Further, the relatively thick flat filament 2a is likely to wave in a predetermined direction (for example, a thickness direction) on the cross section of the FTS 3 when being discharged. Therefore, the resilience (hardness) of the FTS 3 in a predetermined direction can be easily stabilized.

  In the FTS manufacturing apparatus 1, the aspect ratio of the major axis to the minor axis of the opening shape of the first nozzles 217b, 317b, 417b is 2 or more and 10 or less.

  By doing so, the degree of freedom in the wave direction (amplitude direction) of the relatively thick flat filament 2a discharged from the first nozzles 217b, 317b, 417b can be adjusted appropriately. That is, it is possible to prevent the wave direction from being excessively varied in a direction other than the predetermined direction on the cross section (for example, the short direction of the nozzle forming region) or being aligned too much in the short direction. Therefore, it is possible to suppress a decrease in bonding (linking) with another filament 2 adjacent in a direction other than the predetermined direction, and to suppress a local decrease in repulsive force.

<Third embodiment>
Next, a third embodiment will be described. Hereinafter, a configuration different from the first and second embodiments will be described. The same components as those in the first and second embodiments are denoted by the same reference numerals, and the description thereof may be omitted.

  FIG. 10 is a diagram illustrating a main part of a discharge portion of the molten filament 2 of the nozzle unit 17 according to the third embodiment. FIG. 10A is a horizontal cross-sectional view illustrating an example of a nozzle unit 517 according to the third embodiment. FIG. 10B is a horizontal sectional view illustrating an example of a nozzle unit 617 according to a modification of the third embodiment. It is sectional drawing.

  In FIG. 10A, a nozzle group 517a formed at the discharge portion of the molten filament 2 includes a plurality of first nozzles 517b and a plurality of second nozzles 517c. The sectional area (opening sectional area) of the opening of the first nozzle 517b is larger than the sectional area of the opening of the second nozzle 517c. The formation positions of the plurality of first nozzles 517b are gathered in the vicinity of the center in the short direction of the nozzle formation region on the horizontal cross section of the nozzle portion 517. The formation positions of the plurality of second nozzles 517c are gathered near the both ends in the short direction in the nozzle formation region on the horizontal cross section of the nozzle portion 517. In addition, between the adjacent first nozzles 517b, a third nozzle 517ca whose opening cross-sectional area of the opening (see FIG. 6) whose horizontal cross section is not flat is smaller than that of the first nozzle 517b may be formed. .

  In the present embodiment, each of the shapes of the horizontal sections of the openings of the first nozzle 517b and the second nozzle 517c is rectangular. The short direction and the long direction of the first nozzle 517b are the same as the short direction and the long direction of the nozzle forming region on the horizontal cross section of the nozzle portion 517, respectively. The short direction and the long direction of the second nozzle 517c are the same as the long direction and the short direction of the nozzle forming region on the horizontal cross section of the nozzle portion 517, respectively.

The opening cross-sectional area of the first nozzle 517b is 1.60 [mm ² ], and the distance between adjacent first nozzles 517b is set to 10 [mm]. The opening sectional area of the second nozzle 517c is 0.25 [mm ² ], and the distance between adjacent second nozzles 517c and the shortest distance between the first nozzle 517b and the second nozzle 517c are each 6 [Mm]. Note that the shortest distance between the nozzles is not limited to the above example, and can be appropriately adjusted based on the specifications of the resilience and the smoothness of the FTS 3.

  The ratio of the opening cross-sectional area of the second nozzle 517c to the first nozzle 517b is not particularly limited, but is preferably 1.5 or more and 15 or less, more preferably 2 or more and 10 or less, as in the first and second embodiments. It is as follows.

  The relatively thick and flat cross section of the molten filament 2a discharged from the first nozzle 517b tends to gather near the center of the FTS 3 in the thickness direction. Therefore, in the vicinity of the central part in the thickness direction of the FTS 3, the composition ratio of the filament 2a having a relatively thick and flat cross section increases. Further, the filament 2a having a thick and flat cross section preferentially forms a wave in the thickness direction of the FTS 3 (that is, in the short direction in the nozzle forming region on the horizontal cross section of the nozzle portion 217). Therefore, it is possible to suppress a decrease in the repulsive force and obtain a stable repulsive force.

  In addition, the relatively thin and flat cross section of the molten filament 2b discharged from the second nozzle 517c tends to gather near both ends (surface layer) in the thickness direction of the FTS 3. As a result, the vicinity of the end in the thickness direction of the FTS 3 (hard surface layer) is compressed to increase the filament density, but the composition ratio of the relatively thin flat filaments 2b is increased. Furthermore, the relatively thin flat filament 2b preferentially forms a wave in the width direction of the FTS 3 (that is, the longitudinal direction in the nozzle forming region on the horizontal cross section of the nozzle portion 517). Since the wave in the thickness direction is densified by compressing the end portion in the thickness direction, it is easy to form a lump of the relatively thin flat filament 2b. Therefore, it is possible to suppress the hard surface layer from becoming excessively hard, and to further improve the smoothness near the end in the thickness direction (hard surface layer).

(Modified Example of Nozzle Unit 517)
In FIG. 10B, the nozzle group 617a formed at the discharge portion of the molten filament 2 includes a plurality of first nozzles 617b, second nozzles 617c, and third nozzles 617ca. The cross-sectional area (opening cross-sectional area) of each opening of the second nozzle 617c and the third nozzle 617ca is smaller than the cross-sectional area of the opening of the first nozzle 617b. The nozzle portion 617 in FIG. 10B has the same configuration as the nozzle portion 517 in FIG. 10A except that a flat third nozzle 617ca is formed between adjacent first nozzles 617b. Has become.

  In the nozzle portion 617, the relatively thin molten filament 2c discharged from the third nozzle 617ca between the adjacent first nozzles 617b is combined with the relatively thick molten filament 2a discharged from the first nozzle 617b. In addition, the bonding point density per unit volume (linking density) can be increased. Therefore, it is possible to reduce a local decrease in the repulsive force generated at a portion where the coupling point density is low.

  In the present embodiment, the shape of the horizontal cross section of the opening portions of the second nozzles 517c and 617c and the third nozzle 617ca is not limited to the example shown in FIG. 10, but may be other shapes as in the case of the first nozzles 517b and 617b. Since they may be present (see FIG. 9A and FIGS. 9C to 9G), description thereof will be omitted.

  Next, the wave direction in the horizontal section of the FTS 3 of the molten filament 2 discharged from the nozzle portion 517 in FIG. FIG. 11 is a conceptual diagram showing a preferential vibration direction (wave direction) of the molten filament 2 discharged from a nozzle group 517a (see FIG. 10A) composed of flat nozzles. FIG. 12 is a conceptual diagram showing the wave directions of the thick flat filament 2a and the thin flat filament 2b in the FTS 3. 11 and 12 illustrate the case where the horizontal cross-sectional shape of the opening portion of the first nozzle 517b and the second nozzle 517c is rectangular (see FIG. 9B), but is not limited to this example. For example, the same applies to the shapes shown in FIGS. 9A and 9C to 9G.

  In FIG. 11, the first nozzle 517 b is formed such that the minor axis direction of the cross-sectional shape of the opening portion is the minor direction of the nozzle forming region on the horizontal section of the nozzle portion 517. Therefore, the molten filament 2a is preferentially waved in the short direction (for example, the thickness direction of the mattress) of the nozzle forming region on the horizontal section of the nozzle portion 517. Further, the second nozzle 517c is formed such that the minor axis direction of the cross-sectional shape of the opening portion is the longitudinal direction of the nozzle forming region on the horizontal cross section of the nozzle portion 517. Therefore, the molten filament 2 preferentially waves in the longitudinal direction of the nozzle formation region on the horizontal cross section of the nozzle portion 517 (for example, in the width direction of the mattress).

  As shown in FIG. 12, the relatively thick flat filament 2a discharged from the first nozzle 517b preferentially waves in the thickness direction of the FTS 3 (mattress), and the amplitude in the thickness direction becomes larger than the amplitude in the width direction. . On the other hand, the relatively thin flat filament 2b discharged from the second nozzle 517c is preferentially waved in the width direction of the FTS 3 (mattress), and the amplitude in the width direction is larger than the amplitude in the thickness direction.

  When the molten filament 2 is discharged from the nozzle portion 517, the relatively thin flat filament 2b located near the end in the width direction of the molten filament 2 group (that is, the width direction of the FTS 3) It is regulated by 21a, 21b and is compression molded toward the center in the width direction. Therefore, in the surface layer at the end in the width direction of the second group of the molten filaments, the filament density is stabilized, and the filament is easily smoothed. The relatively thick flat filament 2a located near the center in the width direction of the molten filament 2 group (that is, the width direction of the FTS 3) is melted without being restricted by the receiving plates 21a and 21b of the filament bonding portion 21. The filaments 2 are formed so that the amplitude in the width direction (that is, the thickness direction of the FTS 3) of the group of filaments 2 increases. Therefore, the resilience of the FTS 3 is easily stabilized. If the amplitude in the thickness direction is small, the resilience decreases.

  In FIGS. 11 and 12, the shape of the filament 2 is illustrated as a sine curve for simplification of the drawing. However, in actuality, the shape of the filament 2 may be a complicated shape such as a loop or an eight-shape depending on manufacturing conditions. Is formed. Further, in FIGS. 11 and 12, only two types of the first nozzle 517b and the second nozzle 517c are used as shown in FIG. 10A, but for example, as shown in FIG. Alternatively, three or more types of nozzles having different shapes of the horizontal cross section of the opening may be used.

  As described above, in the FTS manufacturing apparatus 1 of the present embodiment, on the cross section, the opening shape of the second nozzles 517c and 617c has a long diameter and a short diameter, and the short diameter is the nozzle forming area on the cross section. Is the inner diameter of the opening shape of the second nozzles 517c, 617c in the longitudinal direction.

  In this case, the cross section of the relatively thin filament 2c discharged from the second nozzles 517c, 617c can be formed into a flat shape having a major axis and a minor axis. Furthermore, when the relatively thin flat filament 2c is discharged, it becomes easier to wave in the longitudinal direction of the region where the nozzle groups 517a and 617a are provided (for example, in the width direction of the FTS3). Therefore, the bonding (linking) with other filaments 2 (particularly, relatively thick filaments 2a) can be promoted, and the bonding strength between the filaments 2 can be improved.

  In the FTS manufacturing apparatus 1, the nozzle groups 517a and 617a further include third nozzles 517ca and 617ca having an opening cross-sectional area smaller than that of the first nozzles 517b and 617b, and intersect with the discharge direction of the molten filament 2. The third nozzles 517ca, 617ca are provided at the center of the cross section in a predetermined direction on the cross section of the nozzle portions 517, 617.

  In this way, the relatively thin filament 2c can also be present at the center in a predetermined direction (for example, the thickness direction) on a cross section that intersects with the direction in which the FTS 3 is formed, and can be combined with the relatively thick filament 2a. Therefore, the bonding point density (linking density) per unit volume in the central portion can be increased, and a stable repulsive force can be obtained. Therefore, for example, it is possible to reduce a local decrease in the repulsive force that occurs at a portion where the coupling point density is small.

  The embodiments of the present invention have been described above. It should be noted that the above-described embodiment is an exemplification, and various modifications can be made to the combination of each component and each process, and it is understood by those skilled in the art that the modification is within the scope of the present invention.

  The FTS3 manufacturing apparatus 1 and the FTS3 manufacturing method according to the present invention can be used for manufacturing FTS3 used for mattresses, pillows, and cushions.

1 ... Filament three-dimensional unit manufacturing equipment (FTS manufacturing equipment)
2 ・ ・ ・ Molten filament 3 ・ ・ ・ Filament 3D assembly (FTS)
DESCRIPTION OF SYMBOLS 10 ... Extruder 11 ... Pressurizing part 11a ... Cylinder 11b ... Filament discharge part 12 ... Die 12a ... Die guide channel 13 ... Hopper 14 ... Screw 15 ... Screw motor 16 (16a, 16b, 16c) ... Screw heater 17, 117, 217, 317, 417, 517, 617 ... Nozzle part 17a, 117a, 217a, 317a, 417a, 517a, 617a .. Nozzle group 17b, 117b, 217b, 317b, 417b, 517b, 617b ... first nozzle 17c, 117c, 217c, 317c, 417c, 517c, 617c ... second nozzle 117ca, 117ca, 317ca, 617ca .... Third nozzle 18 ... -19 (19a, 19b, 19c) ... temperature sensor 20 ... three-dimensional combined body forming device 21 (21a, 22b), 61 (61a, 61b) ... receiving plate 22 ... cooler 22a ··· Cooling water 23 ··· Water tank 24 (24a, 24b) ··· Slat conveyor 25a, 25b, 25c, 25d, 25e, 25f, 25g ··· Transport roller 26 ··· Transport motor 31 ··· Drive gear 32: driven gear 33: guide plate holding member 34: guide plate

Claims (5)

A molten filament supply device for discharging a plurality of molten filaments from a nozzle portion,
A three-dimensional combined body forming apparatus for forming a filament three-dimensional combined body in which the molten filaments are fusion-bonded to each other,
The nozzle unit includes a nozzle group including a first nozzle and a second nozzle having a smaller opening cross-sectional area than the first nozzle.
In a predetermined direction on the cross section of the nozzle portion that intersects with the discharge direction of the molten filament, the first nozzle is provided at a center portion more than an end portion of the cross section, and the second nozzle is provided at a position higher than the center portion. Many are provided at the end ,
On the cross section, the nozzle group is provided in a region having a shape having a longitudinal direction and a transverse direction, and the predetermined direction is the transverse direction,
On the cross section, the opening shape of the first nozzle is a shape having a major axis and a minor axis,
The apparatus according to claim 3, wherein the minor axis is an inner diameter of an opening shape of the first nozzle in the lateral direction . The apparatus according to claim 1, wherein the ratio of the major axis to the minor axis of the opening shape of the first nozzle is 2 or more and 10 or less . On the cross section, the opening shape of the second nozzle is a shape having a major axis and a minor axis,
3. The apparatus according to claim 1, wherein the minor diameter is an inner diameter of an opening shape of the second nozzle in the longitudinal direction . 4. The nozzle group further includes a third nozzle having a smaller opening cross-sectional area than the first nozzle,
4. The apparatus according to claim 1, wherein the third nozzle is provided at a center of the cross section in the predetermined direction . 5. On the cross section, the opening shape of the third nozzle is a shape having a major axis and a minor axis,
The apparatus according to claim 4, wherein the minor diameter is an inner diameter of an opening shape of the third nozzle in the longitudinal direction .