JPH0458357B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to an apparatus for continuously manufacturing a porous cushion material in the form of a thick plate block, which is mainly used for forming cushion surfaces of beds, chairs, etc.

(Prior art) The above porous cushion material is made by intertwining curled fibers, which are monofilament made of 50 to 1000 deniers of three-dimensional curled synthetic resin, especially polyester resin, in a rectangular thick plate shape. death,
This material is impregnated with a rubber-based adhesive liquid and compressed to a predetermined density to form a porous material that looks similar to a loofah core, and is widely used as a cushion substrate for beds, chairs, etc. .

The production of this porous cushion material is partially mechanized, but as a whole it is usually done exclusively by hand in stages, and it is difficult to do it continuously. Ta.

(Problem to be Solved by the Invention) In other words, the above-mentioned work involves gathering the raw material curled fibers into a rectangular plate shape, performing sashimi with a needle to intertwine the fibers, and applying an adhesive of the required concentration to this assembly. There are two types of work: immersing the adhesive in water, and removing it from the adhesive and draining it to reach the desired adhesive content, compressing it slightly to maintain a predetermined porosity, and then heating and drying it to fix it. Of these, the work up to immersion in the adhesive solution can be mechanized and processed continuously. However, subsequent work using the adhesive becomes difficult. In other words, the adhesive liquid used has a relatively low concentration in order to maintain uniform elasticity of the material in the finished porous cushion, and it takes time to drain the adhesive liquid, and the adhesive liquid that has been dripped is not absorbed by the equipment. After it adheres, it gradually dries and increases in viscosity, which becomes an obstacle to transport. Moreover, in order to remove this, the work must be interrupted.

Next, in the compacting stage, when the half-dried material containing the adhesive liquid is compacted to a predetermined void density, it is necessary that the compacted material be maintained in that state to some extent. It was considered to be a hindrance and unsuitable for continuous production.

Under these circumstances, conventionally the material was produced by taking it out of the drying oven and pressing it in a mold.

(Means for solving the problem) To this end, it is necessary to immediately remove the dripping adhesive from the adhesive-impregnated material, and to perform compaction on a moving conveyor instead of by conventional flat plate compaction. The present invention was developed taking the above points into consideration.

(Embodiments of the Invention) In explaining embodiments of the invention, first, the entire apparatus will be schematically explained. In FIG. 1, 1
is a grid lattice conveyor formed by connecting two endless chains on the left and right sides in a large number of horizontal strips.The curled fibers a, which are the raw material fed on this grid conveyor 1 at any time, are scraped off by needle-shaped rollers 2. The air is sucked into the air transport pipe 3 and stored in the metering supply tower 4, and is continuously discharged from the lower part of the tower via the roller feeder 5 onto the transfer conveyor 6, where it is placed in the upper part. After the fibers are adjusted to a constant thickness by compression rollers 7, 7, the fibers are intertwined with each other to form a series of strips by a pair of upper and lower sashiko needles 8, 8 that move up and down in correspondence with each other. After passing through the adhesive liquid tank 11 by the adhesive liquid coating conveyor 10 and immersed in the adhesive liquid, the liquid draining conveyor is housed in one drying oven 18 together with a pressing plate conveyor 14 to be described later. 12, excess adhesive liquid is drained off, and the shaken-off adhesive liquid is collected into a receiver 13. The adhesion force of this adhesive liquid can be easily adjusted by adjusting the concentration of the adhesive liquid, heating temperature, etc.

A series of strip-shaped raw materials that have been drained are transferred to a pressing plate conveyor 14 formed of a large number of perforated plates.
Pressure rollers 15 provided above this plate conveyor 14...
is sequentially compressed by the heating mechanism 16 from below.
The product is then dried by a cutting blade 17 that moves up and down to cut into pieces of a required length to obtain the desired product.

To further explain the liquid draining conveyor 12 and the pressing plate conveyor 14 in the above device, the liquid draining conveyor 12 has a large number of rollers 12b . These rollers 12b... have a sprocket 12c attached to one end thereof, and these rollers 12b...
When b... comes to the return side of the conveyor, it engages with a rack-shaped guide rail 12d attached to the base and rotates. These rollers 12b... are heated by a burner 12e provided on the base to soften and carbonize the adhered adhesive, and then the rollers 12b... …
The surface is cleaned by a rotating brush 12f that rotates in the opposite direction. In this way, the adhesive liquid dripping and adhering to the rollers 12b... is completely removed, and there is no possibility that it will interfere with the function of the conveyor. Note that the rotating brush 12f may be provided above and below the rollers 12b, etc., or may be configured to repeatedly reciprocate in the axial direction via an appropriate link mechanism.

Next, as shown in FIGS. 3A, B, and C, the compacting plate conveyor 14 is gradually lowered forward (to the right in the figure) onto the plate conveyor 14 made of a perforated plate and placed on the pedestal 15a. An endless belt 15 which is mounted on a shaft and is made of a multi-hole connecting plate.
Several pressure rollers 15... are provided with tension rollers 15..., and these pressure rollers 15... are simultaneously rotated by a sprocket 15b and a chain (not shown) connecting them, and each has a feed screw 15d. The mounting height can be adjusted through the The bearings that support both ends of the shafts of the pressure rollers 15 are inserted into the long holes of the pedestal 15a, and after adjusting the installation height with the feed screw 15d, the lock nut 1 is inserted as shown in FIG. 3C.
5e to be fixed to the pedestal 15a. In addition,
Guide plates 14a are provided upright on both sides of the upper surface of the plate conveyor 14 to prevent the material from extruding laterally. Below the plate conveyor 14, a lattice-shaped receiving frame 1 is provided to support the plate conveyor 14 being pressed down by pressure rollers 15.
5f is provided, and a steam ejection pipe or a hot air ejection pipe is provided as the heating mechanism 16. As shown in FIG. 3B, the pressure roller 15... and the roller of the plate conveyor 14 are equipped with gears 15g,
15g, the pressure rollers 15...
... and the transfer speed of the plate conveyor 14 are approximately equal.

(Operations and Effects) This invention has the above-described structure, and the feeding of raw materials, sashiko, immersion in adhesive liquid, draining, pressing, cutting, etc. are performed continuously through each conveyor mechanism, making it extremely efficient. In addition, as mentioned above, especially in compaction, the material moving on the plate conveyor 14 is suspended so that the endless belt is lowered forward so that the material is gradually compacted. The pressure roller 15 whose mounting height is adjustable is used to compress the material to maintain a desired porosity, and the material is heated from below to dry and solidify, thereby shortening the time required to maintain the pressure. In FIG. 3A, each lower pressure roller 15 of the pedestal 15a is used to prevent the endless belt 15c for rolling down from vibrating up and down due to the repulsive force of the moving material.
...It will be more effective if a rise prevention plate is placed in between, and similarly, the plate conveyor 14 for support needs to withstand the pressure that compresses and deforms the material by about 5 to 30% in the thickness direction. , until the heating mechanism 16 completes the heat setting of the plate conveyor 1.
It is advisable to attach a support guide for holding the 4 on a flat surface.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention, and Fig. 1 is an explanatory side view of the entire device, Fig. 2 is a slope view of the main part of the liquid draining conveyor, and Fig. 3 A, B, and C are side views of the compacting process section. , a front view, and a front view of main parts. In the figure, 4 is a constant supply tower, 8 is a sashiko needle, 11 is an adhesive liquid tank, 12 is a liquid draining conveyor,
12a is an endless chain, 12b is a roller, 12
12f is a rotating brush, 13 is a receiver, 14 is a plate conveyor, 15 is a pressure roller, 15d is a feed screw, 16 is a heating mechanism, 17 is a cutting blade, and 18 is a drying oven.

Claims (1)

[Claims] 1 A mechanism for sending out the raw material curl fiber as a series of strip-shaped materials, a mechanism for applying sashiko to this strip-shaped material, a mechanism for immersing it in the adhesive solution, a mechanism for draining off the excess adhesive solution attached, and the drained material. It is a series of devices in which a mechanism for compressing the material from above and below to a predetermined porosity and a mechanism for cutting the compressed material into a certain length are successively installed. On top of a plate conveyor consisting of a perforated plate that moves forward, an endless band of several pressure rollers that rotate inward and are suspended across each other gradually narrows the distance between them and the top surface of the plate conveyor. These pressure rollers are rotated independently at approximately the same speed in opposite directions to the plate conveyor, and are provided with adjustable installation heights, and a heating mechanism is installed below the plate conveyor. 1. An apparatus for continuously manufacturing porous cushion material, characterized in that a device is provided with a porous cushion material.