KR101786215B1 - Pillow manufacturing method - Google Patents

Abstract

The present invention relates to a process for producing a pillow, comprising: a raw material extruding step in which a pillow raw material composed of a thermoplastic resin is put into an extruder and melted and discharged; A continuous molding step of submerging the extruded pillow material into a water tank containing cooling water, continuously forming and cooling a pillow raw material in which a main body of the molding device installed in the water tank is set, and moving the pillow molding to a descending part; Removing the cooling water by moving the pillow-shaped body moved to the lower portion to the outside of the water tank; And a step of processing the molded body from which the cooling water has been removed into a pillow structure. The method of manufacturing a pillow according to the present invention is characterized in that cooling and molding are performed at a uniform size and continuously produced in uniform quality and size. The production process is simplified and the working efficiency is increased.

Description

TECHNICAL FIELD [0001] The present invention relates to a pillow manufacturing method using a mattress molding apparatus,

The present invention relates to a method of manufacturing a pillow using a mattress molding apparatus, and more particularly, to a method of manufacturing a pillow using a mattress molding apparatus, which comprises: a raw material extrusion step in which a pillow raw material composed of a thermoplastic resin is injected into an extruder to melt and discharge; A continuous molding step of submerging the extruded pillow material into a water tank containing cooling water, continuously forming and cooling a pillow raw material in which a main body of the molding device installed in the water tank is set, and moving the pillow molding to a descending part; Removing the cooling water by moving the pillow-shaped body moved to the lower portion to the outside of the water tank; And processing the molded body from which the cooling water has been removed into a pillow structure.

A pillow is a bedding that helps you to get a good night's sleep in a relaxed position by supporting your head when you lie down. The pillow can support the head, and it can be about 6-8cm height without burden on the neck and waist. It is also appropriate that the material of the pillow is formed of a material that absorbs the sweat flowing during sleep and dries quickly.

The type of pillow can be classified as hard, soft, or low depending on the material or contents of the pillow. In the past, pillows were made up of hardened pillows, such as beans, mung beans, and other grain, rice bran, and buckwheat husks, wrapped in fiber, and formed by wood, bruises, and brushes. However, in the modern age, sponges and feathers The pillow with a soft touch was preferred, and the pillow made of a mattress material is the most preferred. The shape of the mattress is a rectangular piece externally providing a cushioning force and a buffering force, and may be formed mainly of latex, urethane foam, polyester staple fiber or the like.

Generally, a method of manufacturing a mattress includes the steps of feeding a raw material into an extruder, molding the molten raw material into a mold in an extruder, And cooling the mold to obtain an injected mattress frame.

When the raw material is put into the extruder, the following series of processes are performed. First, the raw material is compressed under back pressure, and a molten resin film is formed on the surface of the barrel by the barrel temperature and friction with the barrel surface. As the back pressure continues to increase, the friction between the resin particles also increases and the resin becomes easily melted, and when it is almost melted, the homogenization process begins. The mattress raw material melted and introduced into the mold can be cooled at room temperature for a certain time and supplied as a structure.

However, such a manufacturing method requires a complicated work process and a lot of workforce, and as a result, the productivity is very low, which causes a problem that a production cost is greatly increased, and a mold for molding a raw material needs to be manufactured separately.

Korean Patent No. 10-0391512 discloses a polyether polyol obtained by mixing a polyhydric alcohol and a polyether compound at a weight ratio of 3-5: 5-7 to prepare a polyether polyol. 20 to 80 parts by weight of an isocyanate compound is added to 40 to 80 parts by weight of a polyol mixture at a temperature range of 20 to 80 DEG C and the resultant is stirred to obtain a poly A method for producing the same, and a mattress comprising the same. Korean Patent Laid-Open Publication No. 10-2003-0002073 discloses a process for producing a latex comprising aging a latex raw solution for 12 to 36 hours and then adding additives such as a vulcanization accelerator, a vulcanizing agent, a hardening agent, a hardening accelerator, an oxidizing agent, Whipping the latex stock solution for 30 to 40 minutes; Injecting a foamed latex stock solution into a mold, curing at 105 to 115 ° C to form a molded body; A method of manufacturing a latex mattress and a functional latex mattress comprising the steps of washing the molded latex raw material with water and drying the washed latex at a temperature of 50 to 60 ° C. In Korean Patent No. 10-0503392, a resin premix (liquid A) such as a polyol, a crosslinking agent, a catalyst, a foaming agent and an additive, and a resin pre-mix such as a polyol, a foaming agent and an additive are added to a lower mold having a substrate of a mattress and a cavity portion corresponding to a plurality of cushion protrusions formed on the substrate (B liquid) roll mixture, and thereafter a plurality of cushion protrusions are formed by merging and demolding, and a manufacturing method thereof. Korean Patent Laid-Open Publication No. 10-2005-0010026 discloses a method of manufacturing a semiconductor device having a receiving portion having a predetermined depth and a cavity portion formed of a plurality of recesses formed at regular intervals in the receiving portion and having a diameter or a diagonal length of 30 to 120 mm The mold may be provided with a single or two or more types of polyurethane resin, polyvinyl chloride resin, polyolefin resin, polyvinyl alcohol resin, polystyrene resin, NBR latex, SBR latex, phenol resin, melamine resin, A foamed resin obtained by mixing foamed resin is injected and subjected to foam molding, and a cushioning material produced thereby.

In order to solve the above problems, the present invention is characterized in that the molten pillow material is laminated in a water tank containing cooling water, and not only the molding and cooling can be carried out at the same time, but also by using a molding apparatus in which the processes are continuously carried out, A raw material extrusion step in which a raw material for a pillow is injected into an extruder to melt and discharge the raw material; A continuous molding step of submerging the extruded pillow material into a water tank containing cooling water, continuously forming and cooling a pillow raw material in which a main body of the molding device installed in the water tank is set, and moving the pillow molding to a descending part; Removing the cooling water by moving the pillow-shaped body moved to the lower portion to the outside of the water tank; And processing the molded body from which the cooling water has been removed into a pillow structure. The present invention also provides a method of manufacturing a pillow using the mattress molding apparatus.

In order to accomplish the above object, the present invention provides a method of manufacturing a pillow, comprising: a raw material extruding step in which a pillow raw material composed of a thermoplastic resin is put into an extruder and melted and discharged; A continuous molding step of submerging the extruded pillow material into a water tank containing cooling water, continuously forming and cooling a pillow raw material in which a main body of the molding device installed in the water tank is set, and moving the pillow molding to a descending part; Removing the cooling water by moving the pillow-shaped body moved to the lower portion to the outside of the water tank; And a step of processing the pillow-shaped body from which the cooling water is removed into a pillow structure.

The present invention relates to a mattress molding machine and a method of manufacturing a mattress molding machine, which, when a melted pillow material is submerged in a water tank containing cooling water, can be formed into a uniform size at the same time as cooling and can be continuously produced with uniform quality and size, The manufacturing process is simplified and the working efficiency is increased.

1 is a schematic view of a method of manufacturing a pillow using a mattress molding apparatus according to the present invention.
Fig. 2 shows a mattress molding apparatus for manufacturing a pillow using the mattress molding apparatus of the present invention.
Fig. 3 shows an extruder of the mattress molding apparatus of the present invention.
4 shows a side view and a front view of the body of a mattress molding apparatus according to the present invention.
5 shows the body of the drawing apparatus of the mattress molding apparatus of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a detailed description will be made with reference to specific configurations and accompanying drawings relating to a method of manufacturing a pillow using a mattress molding apparatus according to the present invention.

1 is a schematic view of a method of manufacturing a pillow using a mattress molding apparatus according to the present invention. A method of manufacturing a pillow using a mattress molding apparatus according to the present invention includes: a raw material extrusion step in which a pillow raw material composed of a thermoplastic resin is charged into an extruder and melted and discharged; A continuous molding step of submerging the extruded pillow material into a water tank containing cooling water, continuously forming and cooling a pillow raw material in which a main body of the molding device installed in the water tank is set, and moving the pillow molding to a descending part; Removing the cooling water by moving the pillow-shaped body moved to the lower portion to the outside of the water tank; And processing the molded body from which the cooling water has been removed into a pillow structure.

2 is a side sectional view of a mattress molding apparatus in a method of manufacturing a pillow using the mattress molding apparatus of the present invention. The mattress molding apparatus used in the pillow manufacturing step of the present invention includes an extruder 10 in which a pillow material is charged and melted and discharged; A water tank (20) composed of a polygonal water tank bottom and an outer wall of the water tank, the raw material discharged through the upper opening being stacked in the water tank; A main body 40 of a molding apparatus installed inside the water tub to form a laminated raw material into a predetermined frame; A take-up device main body (30) spaced apart in a direction symmetrical to the main body of the molding apparatus and continuously moving the pillow material stacked in the spacing space in a downward direction; And a mattress transferring unit (50) for transferring the pillow material lowered by the main body of the drawing device to the outside of the water tank.

The raw material extruding step of the present invention may be performed in an extruder of a mattress molding machine. Fig. 3 shows an extruder of the mattress molding apparatus of the present invention. The extruder 10 includes a hopper 11 into which a raw material for a pillow is injected into the extruder, a heating unit main body 12 for compressing, melting, conveying and homogenizing the cylinder and the pillow material into which the screw is inserted, And a die 13 for discharging the raw material of the pillow melted in the main body toward the water tank opening. The dies of the present invention may be stacked in the water tank while one or more of the dies are installed and the molten pillow material is discharged in the form of one or more threads.

The pillow material W to be fed into the hopper is generally made of a thermoplastic resin so as to facilitate chemical reaction such as crosslinking reaction and molding conditions so that an extrusion molding process can be performed in an extruder. The continuous molding step of the present invention may be carried out through a main body of the molding apparatus installed in the water tank of the mattress molding apparatus, and the cooling water contained in the body of the drawing apparatus and the water tank.

The water tank is composed of a polygonal water tank bottom and an outer wall of the water tank, and the raw material of the pillow at a high temperature discharged from the extruder through the upper opening of the water tank can be introduced into the water tank. The water tank contains the cooling water 21 at a level that does not overflow when the discharged pillow material is stocked in the water tank.

The cooling water is suitably about 30 to 50 ° C. The material of the pillow can be solidified by simple cooling process such as water tank, cooling water spray, air-cooling and the like, and the range of the cooling water temperature is such that when the pillow material is put into the water tank, And the pillow material is laminated in a semi-solid state, and is suitable for forming a constant frame in the main body of the molding apparatus.

The body of the molding apparatus and the body of the drawing apparatus are spaced apart from each other by a predetermined distance in a direction symmetrical to each other within the water tank, and the high-temperature pillow material discharged from the extruder may be stacked in the above- The separation distance between the body of the molding apparatus and the body of the drawing apparatus is the same as the thickness of the pillow. The laminated pillow material is laminated and the frame is formed by the body of the molding apparatus and simultaneously cooled.

4 is a side view and a front view showing the main body of the mattress molding apparatus according to the present invention. In the molding apparatus main body of the present invention, one or more shaping rollers 43 are installed spaced apart in the upward and downward directions, A forming belt 41 is formed surrounding the forming roller.

At least one molding frame 44 is formed at regular intervals so that pillow raw materials can be laminated on the surface of the molding belt and can be molded into a predetermined shape. The injection holes 42 Is formed.

A cooling water tank 45 for injecting high-pressure water is provided between the upper shaping roller and the lower shaping roller for supporting the shaping belt, and a cooling water injection nozzle 46 for injecting high pressure in the cooling water tank in the direction in which the pillow is formed .

The injection hole forming position of the molding belt is formed at a position where it can be connected to the installation position of the cooling water injection nozzle at regular intervals, and the cooling water is injected through the injection hole so that the cooling water to be injected can pass therethrough.

The forming rollers are spaced apart from each other in the upward and downward directions of the water tank, and the forming belt rotates at a constant speed around the forming roller as a central axis. The rotation speed of the shaping roller is a time at which the pillow material is allowed to move after being formed into a predetermined shape by being stacked at a constant weight and becoming a solid. The pillow material is stacked and formed into a predetermined frame, and then the pillow material is moved to the mattress moving part while pushing the molded body downward by rotational motion.

Since the pillow raw material discharged from the extruder is in a high temperature state, when the pillow material is stacked, the water temperature of the cooling water rises, and when the molded body is pushed out by the rotation of the molding belt, the pillow material is not cooled as a whole, .

In the space between the forming frames, the spray holes provided for spraying the cooling water continuously to the pillow material to be stacked can keep the cooling water in the lamination part at a constant water temperature. It can also continuously filter out foreign matter mixed with semi-solid pillow materials at high flow rates.

The supply and blocking of the cooling water can be accomplished by rotating the molding belt. The high-pressure injection hole formed in the cooling water tank coincides with the injection hole formed in the molding belt or the molding frame, so that the high-pressure cooling water is injected in the direction of the pillow mold body. Since the molding belt continuously rotates, if it is inconsistent with the contact surface between the injection hole and the cooling water injection nozzle, the cooling water injection is automatically blocked by the belt surface.

The cooling water injection nozzle includes oxygen tube and compressor, oxygen is supplied through the oxygen tube, and the compressed oxygen is compressed by the high pressure oxygen to supply the high-pressure cooling water. Not only can the foreign matter be filtered more precisely through high-speed cooling water injection, but even if the high-temperature melted pillow material is stocked, uniform water temperature maintenance is possible so that set temperature and temperature difference do not change.

5 shows the body of the drawing apparatus of the mattress molding apparatus of the present invention. The take-up device body is spaced apart from the main body of the molding machine by a predetermined distance in a direction symmetrical with respect to the main body of the molding device. And a take-up roller (32) for imparting power to move the sheet.

The drawing roller 32 is provided with an upper drawing roller and a lower drawing roller in an upward and downward direction at a position spaced from the forming roller of the molding apparatus main body by a predetermined distance, And a tilting roller is provided while forming an angle. The draw belt is formed while surrounding the draw rollers, and the lowermost portion of the draw belt forms an inclination at an angle formed by the warp draw roller with the lower draw roller. Therefore, the laminated and formed mattress can be moved downward along the inclination to the mattress conveying portion.

The raw material of the pillow is made of a thermoplastic resin and has a smaller specific gravity than the cooling water, and when the molten pillow material is stocked in the cooling water, the pillow is floated to the water surface by buoyancy. Therefore, the main body of the drawing apparatus performs a role of fixing the pillow material so as not to float when the pillow material is formed, and a role of both areas moving the pillow molding body to the mattress transferring unit by rotating at a time interval that the pillow- Further, since the rotation speed of the body of the molding apparatus and the body of the drawing apparatus can be adjusted, it is also possible to produce pillows of various strengths.

The cooling water removing step is a step of removing the cooling water of the molded body while vibrating for a predetermined time by moving the pillow-shaped body through the mattress conveying part to a vibrator provided outside the water tank.

The vibrator may be operated by a left-right vibration or an up-and-down vibration, and the transfer portion to which the mattress is transferred may be formed of a plate having a mesh shape so as to be able to process the separated cooling water by vibration. Further, the high-pressure air is injected together at the upper portion or the lower portion while the vibrator is driven, whereby the remaining amount of cooling water to be conveyed together with the pillow molding can be separated.

The processing step may generally consist of a cutting step, an edge application step, and a pillow skin drying step. The cutting step is a step of cutting the pillow molded body from which cooling water has been removed in the cooling water removing step to a predetermined standard.

The edge application step may generally consist of an application step, a cooling step, and a drying step. The application step may be such that the pillow finished with the cutting step is formed into a thread of several hundreds or several thousands of diameters of 0.2 to 1.5 mm so that the corner portion is very sharp and dangerous to the user, To about 5 mm thick.

In the coating step, a method may be considered in which the corners are immersed in the raw material container containing the molten raw material for the pillow for a certain period of time, and then the molten sound is introduced into the mold in which the pillow corner mold is embedded. In addition, the molten pillow material can be applied directly to the edge of the pillow and molded into a mold frame, so that the application process of the corner portion can be performed. Extrusion of compact extruder (thickness 0.3 ~ 1mm) Dies are made by extruding the same raw material as the pillow raw material, and the molten resin is compressed 20 ~ 80% of the cut pillow edge and then cut to 0.5 ~ 5mm thickness When laminated and cooled, the sharp side of the cut side is coated with resin to improve the side portion.

In the cooling step, the coated pillow is immediately immersed in the cooling water of 30 to 50 ° C. to fix the pillow material to be crystallized and kept in a cooled form. The drying step is to completely dry the cooling water in the cooling step, and the drying temperature should be dried for a certain time at a temperature of 10 ㅀ or less than the resin melting temperature so that the pillow material can be crystallized and annealed.

The pillow epidermal packing step may be packed with fibers having various materials according to the purpose, such as natural fibers, synthetic fibers, functional fibers and the like, which are excellent in permeability to the pillow which has undergone the edge application step.

It is possible to improve the formability of the pillow member by using the thermoplastic resin as a raw material and to reduce the manufacturing cost by simplifying the manufacturing process of the pillow, It is possible to produce a quality pillow, which can be used industrially because it can provide a high quality pillow to the consumer and enhance the profit of the industry.

10: extruder 11: hopper 12: heating unit main body
13: Dice 20: Water tank 21: Cooling water
30: pickup apparatus main body 31: draw belt 32: draw roller
40: forming device body 41: forming belt 42:
43: forming roller 44: forming frame 45: cooling water tank
46: cooling water spray nozzle 50: mattress conveying part
W: pillow raw material

Claims (6)

A pillow material is introduced through a hopper into which a raw material for a pillow made of a thermoplastic resin is injected, a heating unit body for melting the raw material for the pillow, and an extruder comprising a die for discharging the raw material of the pillow to the water tank opening, A raw material extruding step of discharging the raw material into the water tank;
The water tank is provided with a molding apparatus main body in which a forming belt is surrounded by a forming roller spaced upward and downward. A cooling water tank for injecting high-pressure water is installed between the upper forming roller supporting the forming belt and the lower forming roller And,
Wherein at least one molding frame is formed at a predetermined interval on the molding belt and cooling water injection nozzles are formed at regular intervals so that the cooling water tank can be injected in a direction in which the pillow is molded,
A space between the molding frame or the molding frame is formed with a spray hole to be connected to the cooling water spray nozzle so that the cooling water is injected into the pillow molding body at a high pressure so that the pillow material is continuously cooled and simultaneously molded, A continuous forming step of moving the pillow molded body to a descending portion;
Removing the cooling water by moving the pillow-shaped body moved to the lower portion to the outside of the water tank; And a step of processing the pillow-shaped body from which the cooling water has been removed into a pillow structure.
The mattress molding apparatus according to claim 1, wherein the cooling water removing step removes the cooling water of the pillow-formed body by moving the pillow-shaped body moved to the lowered portion through a conveying portion to a vibrator provided outside the watertank, Method of manufacturing a pillow using
The method according to claim 1, wherein the processing step comprises a cutting step of cutting the pillow-shaped body from which cooling water has been removed to a predetermined standard, a corner applying step of applying pillow material to the edge of the cut pillow, And a method of manufacturing a pillow using the mattress molding apparatus
The method according to claim 3, wherein the edge applying step comprises a coating step of immersing the corner of the pillow in a raw material container containing the molten raw material for the pillow for a predetermined time, a cooling step of soaking the pillow in the cooling water at 30 to 50 ° C, And a drying step of crystallizing and annealing at a temperature of 10 ° C or lower than the melting temperature of the resin after the cooling step delete delete

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