KR101253731B1 - Cushion of manufacturing methods - Google Patents

Abstract

PURPOSE: A manufacturing method of a cushion material is provided to have a fixed thickness and density by controlling the height of a laminated material by supplying air when supplying fiber-opened yarn. CONSTITUTION: A manufacturing method of a cushion material includes: a step of supplying fiber-opened yarn and air to a housing, laminating the yarn by the air pressure of supplied air, and having a cushioning effect by filling air between the laminated yarns; a step discharging the yarn supplied to the inside of the housing and discharging air through an air discharging part installed in the lower part of the housing; a step of stopping yarn supply by detecting the height of the laminated material if the height is over a control height defined by a height controlling part which is comprised of a photo sensor installed inside of the housing; a step of supplying yarn again if the height of the laminated material is below the control height and spraying air from a flattening part in the crossing direction to the top end part of the laminated material so that the top end part of the laminated material inside of the housing becomes flat. [Reference numerals] (10) Housing; (20) Thickness control; (30) Yarn arrangement; (40) Height control; (50) Air discharge; (60) Air spray; (AA) Stop/resupply signal; (BB) Yarn and air supply;

Description

Cushion of manufacturing methods

The present invention relates to a method of manufacturing a cushioning material, and more particularly, to a method of manufacturing a cushioning material having a constant thickness and density by supplying air together with a yarn to randomly stack yarns and adjusting height.

Generally, cushion material using polyester has been mainly used for bedding such as bed mattress material, but recently, it is harmless to human body compared to the existing insulation and sound absorbing material such as glass wool or rock wool, and is an environmentally friendly material that can be recycled. As a substitute for these, they are attracting much attention.

As a general method of producing a plush, the low melting point short fibers and the high melting point short fibers having different melting points shown in FIG. 1 are opened with a yarn-like yarn using the opening means 100, and the opened fibers are fixed. The carding means 200 having a thickness and a width is used to form a web.

The web formed by the carding means 200 is spread evenly on the conveyance belt and the web is laminated several times using the web laminating means 300 to form a constant thickness to form a web laminate.

While transferring the web laminate formed by the web laminating means 300 to a predetermined height to the transfer belt while passing through the heating / pressing means 400, the web laminate is pressed at the same time with the heating is laminated to a constant thickness, for example 300mm The web laminate is formed to have a thickness of 50 mm to produce a general cushion material having a high density.

The general plush is a web produced by the carding means (200) by laminating a plurality of webs by the web laminating means (300) and then look at the plush produced by pressing the heating and pressing at the same time by the heating / crimping means (400) It is easy to confirm that this laminate was made.

As described above, the conventional method for manufacturing the silk noodle is manufactured in the order of short fiber → opening → web manufacturing → web lamination → heating / compression → cooling, and the web is formed in the form of a sheet having a predetermined thickness and width to be laminated in multiple layers and hot pressed. Since the gap between the short fibers and the short fibers is low, the water permeability is significantly low. As described above, the conventional plush layer laminated in layers by the metal carding method allows web bonding to be laid horizontally and horizontally by the carding means. There was a problem that the elasticity and the restoring force is deteriorated due to the characteristics of the plush receiving the force vertically and the web and the web is easily peeled off each other.

On the other hand, since the web laminate, in which the yarns are neatly arranged by the carding means, is pressed at high density during heat pressing, there is no space formed between the short fibers and the short fibers, so that the sound absorption and moisture permeability are significantly reduced. There was this.

The present invention has been made in view of the conventional problems, and an object of the present invention is to supply the opened yarn with air at the time of supplying the cushioning material to have a constant thickness and density by controlling the height of the laminated laminate laminated by the supplied air To provide a method of manufacturing.

Meanwhile, the top of the yarns stacked inside the housing are sprayed to maintain a flat surface so as to be uniformly laminated so that the density of the product is partially different from each other, and between the yarns in which the air supplied with the yarns is stacked. The present invention provides a method for producing a cushioning material that can be filled with excellent elasticity and resilience, and a cushioning material having excellent sound absorption and moisture permeability.

Another purpose is to change the inner area of the housing to control the thickness of the laminated laminate to be blown out in disorder by the air supplied, and the elasticity and resilience by adjusting the density while shaking the stacked yarn is excellent, sound absorption and moisture permeability It is to provide a method for producing a cushioning material that can produce this excellent cushioning material.

The object of the present invention is a method of manufacturing a cushioning material, supplying the opened yarn and air to the housing and the yarn is laminated by the pressure of the supplied air, the air is filled between the laminated yarn has a cushioning feeling, the housing Yarn supplied therein is discharged through the stack outlet and air is discharged by the air discharge means provided in the lower part of the housing, and when the stack is stacked up to the height controlled by the height adjusting means installed in the housing, the stack is stacked in the height adjusting means. It is achieved by a method for producing a cushioning material, characterized in that the yarn supply is stopped by detecting the height of the laminated stack.

The height adjusting means is achieved by a method for producing a cushioning material, characterized in that the photosensor.

It is achieved by a method for producing a cushioning material, characterized in that the air is injected in the direction intersecting the top end of the laminate so that the top end of the laminate laminated inside the housing becomes a plane.

Method of manufacturing a cushioning material, characterized in that for adjusting the thickness of the laminate laminated inside the housing by adjusting the movement interval of the flow plate by rotating the pinion gear installed in the flow plate along the rack gear provided on one side of the housing Is achieved.

One side of the housing is achieved by a method for producing a cushioning material, characterized in that the eccentric shaft rotated by the drive motor is connected to the yarn heat plate to shake the yarn heat plate that is the side of the housing to align the stack.

The present invention as such

First, when the opened yarn is supplied with air to be laminated by the supplied air to adjust the height to have a constant thickness and density,

Second, to prevent the agglomeration by spraying air so that the upper end of the laminated yarn inside the housing to maintain a flat surface to be uniformly and evenly stacked, the air supplied with the yarn is filled between the yarn is laminated elasticity and resilience Is excellent, can produce a cushioning material excellent in sound absorption and moisture permeability,

Third, it adjusts the thickness of the laminated laminated by changing the inner area of the housing to be blown by the air supplied, and adjust the density while shaking the stacked yarn to excellent elasticity and resilience, excellent sound absorption and moisture permeability It is a useful invention with advantages.

1 is a manufacturing process of the cushioning material showing a general manufacturing method of the cushioning material.
Figure 2a and Figure 2b is a schematic view of a cushion material manufacturing apparatus showing a method of manufacturing a cushion material to which the technique of the present invention is applied.
Figure 3 is an exemplary view showing a method of manufacturing a cushioning material applied technology of the present invention.
Figure 4 is a cross-sectional view showing the structure and operation of the height adjusting means and the flat means of the technical point of the present invention.
Figure 5 is an exemplary view showing a density control method which is a technical point of the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Figure 2a and Figure 2b is a schematic view of a cushioning material manufacturing apparatus showing a method of manufacturing a cushioning material to which the technology of the present invention is applied, Figure 3 is an exemplary view showing a method of manufacturing a cushioning material applied to the technology of the present invention according to the present invention to manufacture a cushioning material The method forms a yarn inlet and a yarn outlet and adjusts the amount of movement of the housing 10 having a space in which yarns are stacked inside and a flow plate 21 reciprocated in a horizontal direction and installed at one side of the housing 10. Yarn alignment means for arranging the yarns installed in the housing 10 so as to rotate the hinge means in the other direction of the thickness adjusting means 20 and the thickness adjusting means 20 of the inner space 33 ( 30) and a height adjustment means 40 which detects the height of the laminated stack installed on the housing side and stops the yarn supply when the height of the laminated stack is stacked higher than the set height. To produce a cushion material by using a material producing apparatus.

In the manufacturing method of the cushioning material, the position of the height adjusting means 40 is adjusted before feeding the yarn into the housing 10 through the yarn inlet. The height adjusting means 40 uses a photo sensor 41 consisting of a light receiving unit and a light emitting unit in a conventional manner, the photo sensor 41 is a structure installed to be movable along the guide bar 42 provided on the viewing window side.

The installation position of the photosensor 41 is installed in the see-through window provided on the side of the housing because of the characteristics of the sensor when the position is adjusted by moving the position of the photosensor 41 along the guide bar 42 in the vertical direction This is because the light-receiving unit and the light-emitting unit should operate by sending and receiving signals, and also to enable visual confirmation.

In addition, it is preferable that a plurality of photosensors 41 be provided. The reason for this is that an error is likely to occur when only one photo sensor 41 is installed. Thus, when the signals detected by the plurality of photo sensors 41 operate in the same manner, the yarn is supplied and stopped by using the detected information. This is to prevent the error operation of the photosensor 41 by adjusting the.

After adjusting the position of the photosensor 41 consisting of the light-receiving unit and the light-emitting unit supplies a yarn into the housing 10 through the yarn inlet, together with the yarn to supply air together. The supplied yarn is blown by air and randomly laminated, and the laminated material is laminated while being compressed by air, and air is filled between the laminated yarns to have a cushioning and restoring force.

In addition, since the laminate is laminated in a random manner, the cushioning and restoring force are excellent, but sound absorption and moisture permeability are also excellent. The reason why the cushioning and restoring force is improved is that the air supplied as a yarn inside the housing 10 is spaced by the air discharged when the air is discharged by the air discharge means 50 provided below the housing 10. ) Is generated. In addition, the air discharge means 50 prevents the internal pressure generated inside the housing 10.

When the stack is stacked up to the height controlled by the height adjusting means 40 installed inside the housing 10, the height of the stack is detected by the height adjusting means 40 to stop the yarn supply.

Meanwhile, as shown in FIG. 4, when the height adjusting means 40 is adjusted and yarns are stacked inside the housing 10, the height adjusting means 40 is piled higher than the height of the height adjusting means 40. It detects this and cuts the yarn supply (the description of the control device is omitted).

In addition, air is jetted by the plane holding means 60 in a direction intersecting with the uppermost end of the stack so that the uppermost end of the laminate stacked inside the housing 10 becomes a plane, thereby flattening the uppermost end.

If the height of the laminated stack is stacked only in the center side as shown in Figure 4 attached to the high density of the central side, there is a problem that the density of the center side is low when the side is high.

According to the lamination form, it is possible to produce a cushioning material having a uniform density, but when the center part is laminated high, it is also possible to produce a central part high density product suitable for the characteristics of the mattress that takes a lot of load in the center part.

Preferably, the plane holding means (60) uses a spray nozzle and installs a plurality in the housing (10) at regular intervals, and the height of the yarn stack according to the height information detected by the height adjusting means (40). If it is below a certain amount, the yarn will be supplied. If it exceeds a certain time, the yarn will be stopped.

The reason for adjusting the height of the stack is that when the height of the yarn stacking is less than a certain level, the efficiency of compression is reduced together with the stacking by the compressed air, and the stacked stack is broken due to a small amount of stacking when the stacked yarn is continuously discharged. This is because when the height of the yarn stacking is more than a certain amount, it is difficult to control the density by the stacked weight.

Therefore, the laminate laminated randomly within a certain height range is because the density is stably adjusted, the density of the product is uniformly formed, the elasticity and resilience is excellent, and the sound absorption and moisture permeability is excellent.

If you look at this through experiment

Type of yarn: Polyester staple fiber.reqular type

Yarn Length: 64mm

Yarn Thickness: 15denier

Stack height: 1500mm

Stack thickness: 100mm

Looking at the density of the cushioning material at the time of supplying air and not supplying air according to the height of the laminate is as shown in Table 1 below, and the elastic force is shown in Table 2 (non-operation of yarn heat plate).

Stack height   2,000 mm 1500 mm 1,000 mm When air is not supplied 20㎏ / ㎥ 17㎏ / ㎥ 15㎏ / ㎥ When supplying air 30㎏ / ㎥ 24㎏ / ㎥ 20㎏ / ㎥

Stack height  2,000 mm  1500 mm 1,000 mm When air is not supplied Elasticity / Restoration Rate 60% Elasticity / Restore Rate 53% Elasticity / Restoration 45% When supplying air 95% elasticity / restore rate 80% elasticity / restore rate Elasticity / Restore Rate 65%

As can be seen in Table 1 and Table 2, when laminating yarns while supplying air when laminating yarns together, it can be seen that the density of the cushioning material is higher and the elastic force is improved than when air is not supplied.

In addition, by varying the loading amount of the stack stacked in the housing by adjusting the height of the photosensor 41, the height adjusting means 40, the density is different, the higher the loading amount is increased the pressure, the higher the density, the more elastic Is increased.

On the other hand, another method of adjusting the density of the cushioning material is a method of adjusting the thickness of the laminate or aligning the laminated yarn as shown in the accompanying drawings, FIGS. 2A, 2B and 5.

 The method of adjusting the thickness by adjusting the thickness of the first position is the position of the height adjusting means 40 before supplying air and yarn into the housing 10 through the yarn inlet as shown in FIGS. 2A, 2B and 5. After adjusting the thickness of the inner space 33, the thickness of the inner space 33 by adjusting the amount of movement of the flow plate 21 using the thickness adjusting means (20).

In the figure, the rack gear and the pinion are shown, but the cylinder can be used, and the motor and the guide can be used for automatic control. The position adjusting structure of the flow plate 21 is not limited in the present invention.

Meanwhile, the stacked yarn is aligned by the yarn alignment means 30 installed in the housing 10 so that the hinge rotates in the other direction of the thickness adjusting means 10 as shown in FIGS. 2A, 2B and 5. Aligned.

The operation of the yarn alignment means 30 is the yarn alignment plate 31 on one side of the housing 10 by using the eccentric shaft 33 rotated by the driving force of the driving motor to the center of the hinge shaft 36 of the upper end. It rotates and arranges the laminated yarns.

When the air was supplied using the yarn alignment means 30 and the heights were different, the density of the yarns of the stack and the alignment of the yarns was not shown. As shown in Table 3 below.

Stack height 2,000 mm 1500 mm 1,000 mm Yarn misaligned 30㎏ / ㎥ 24㎏ / ㎥ 20㎏ / ㎥ Yarn alignment 38㎏ / ㎥ 29㎏ / ㎥ 24㎏ / ㎥

The density of the product can be adjusted by adjusting the pressure of air supplied into the housing, the vibration range of the height of the stack stacked in the housing 31, and the strength and strength of the stack.

As described above, when the laminate having the thickness and density controlled is discharged at a constant speed by using the discharge means 80 provided in the housing 10 and then heat-compressed, the tissue is random and has excellent elasticity and resilience, The cushioning material excellent in moisture permeability can be manufactured.

10: housing 20: thickness adjusting means
21: fluid plate 30: yarn alignment means
33: space 40: height adjusting means
41: photo sensor 42: guide bar
50: air discharge means 60: plane holding means

Claims (5)

In the manufacturing method of the cushion material,
Supplying the opened yarn and air to the housing and the yarn is laminated by the pressure of the supplied air, the air is filled between the laminated yarn to have a cushion feeling,
Yarn supplied inside the housing is discharged through the stack outlet and air is discharged by the air discharge means provided in the lower housing,
When the stack is stacked above the height adjusted by the height adjusting means made of the photosensor installed inside the housing, the stack height is detected so that the yarn supply is stopped. A method of manufacturing a cushioning material, characterized in that air is sprayed from the flattening means in a direction intersecting with the top end of the stack such that the top end of the laminate stacked inside the housing becomes flat. delete delete The method of claim 1,
Method of manufacturing a cushioning material, characterized in that for adjusting the thickness of the laminate laminated inside the housing by adjusting the movement interval of the flow plate by rotating the pinion gear installed in the flow plate along the rack gear provided on one side of the housing . The method of claim 1,
One side of the housing is eccentric shaft rotated by the drive motor is connected to the yarn heat plate, the yarn heat sink plate which is the side of the housing by shaking the stacking material is characterized in that the stack is aligned.

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