WO2017199474A1 - Device for manufacturing three-dimensional filament conjugates, and method for manufacturing three-dimensional filament conjugates - Google Patents

Abstract

Provided is a device for manufacturing three-dimensional filament conjugates, the device being provided with: a molten filament supply device for discharging molten filaments from each of a plurality of nozzles; and a three-dimensional conjugate-forming device for forming three-dimensional filament conjugates by fusion bonding the discharged molten filament groups. The molten filament supply device has an opening/closing part for opening and closing at least one specific nozzle from among the plurality of nozzles.

Description

Filament three-dimensional combined body manufacturing apparatus and filament three-dimensional combined body manufacturing method

The present invention relates to an apparatus for manufacturing a filament three-dimensional combination and a method for manufacturing a filament three-dimensional combination.

As a highly repulsive cushioning material used for mattresses, pillows and the like, a filament three-dimensional bonded body in which a plurality of thermoplastic resin fibers (molten filaments) in a molten state are three-dimensionally fused and bonded has recently attracted attention.

For example, in Patent Document 1, after a molten thermoplastic resin is extruded vertically downward from a plurality of nozzles arranged horizontally, a molten filament is dropped into cooling water to form a loop, and at the same time, a loop is formed. An apparatus for manufacturing a filament three-dimensional bonded body by three-dimensionally fusing and bonding a plurality of molten filaments is disclosed.

The molten filaments that are fusion-bonded to each other are conveyed to the downstream side while being cooled to form a filament three-dimensional combination continuous in the conveying direction. This filament three-dimensional conjugate | bonded_body is cut | disconnected for every length according to the dimension of the product, and the filament three-dimensional conjugate | bonded_body for the said products is obtained sequentially.

JP 2010-154965 A

The cross-sectional dimension of the three-dimensional filament assembly formed by the above apparatus is closely related to the arrangement of a plurality of nozzles. For example, when the arrangement interval of the nozzles is fixed, when manufacturing a filament three-dimensional combination for a product having a large thickness, a larger number of nozzles are arranged in the direction corresponding to the thickness.

However, since the arrangement state of the nozzles is fixed, for example, it is difficult to appropriately form a three-dimensional filament combined body whose thickness changes in the conveyance direction. Therefore, in order to obtain a filament three-dimensional combination whose thickness varies in the length direction, it is necessary to superimpose two or more filament three-dimensional combinations so as to have a desired thickness, or to cut off the surface. There is a problem that the manufacturing cost becomes high. Also, it is not easy to produce a filament three-dimensional combination by adjusting the hardness (that is, adjusting the filament density).

Thus, in the conventional apparatus, it is not easy to manufacture a three-dimensional filament bonded body by adjusting the thickness dimension and hardness. In view of the above-described problems, the present invention provides a filament three-dimensional joined body manufacturing apparatus and a filament three-dimensional joined body manufacturing method that make it easy to manufacture a filament three-dimensional joined body by adjusting thickness dimensions, hardness, and the like. Objective.

The filament three-dimensional joined body manufacturing apparatus according to the present invention forms a filament three-dimensional joined body by fusion-bonding the molten filament supply device for discharging the molten filament from each of a plurality of nozzles and the discharged molten filament group. The molten filament supply device includes an opening / closing portion that opens and closes a specific nozzle that is at least one of the plurality of nozzles. According to this structure, it becomes easy to manufacture a filament three-dimensional conjugate | bonded_body by adjusting a thickness dimension, hardness, etc.

More specifically, in the above configuration, the opening / closing part includes a shutter member that is movable between an open position that opens the opening and a closed position that closes the opening so that the surface including the opening of the specific nozzle slides. It is good also as a structure which opens and opens by moving the said shutter member. According to this configuration, the specific nozzle can be opened and closed with a simple configuration.

More specifically, the configuration includes a plurality of the specific nozzles arranged in a predetermined direction, and the shutter member has an opening corresponding to each of the specific nozzles and is formed to be movable in the predetermined direction. The open position is a position where the opening overlaps the corresponding specific nozzle, and the closed position is a position where the opening is located between the corresponding specific nozzle and the adjacent specific nozzle. It is good also as a structure which is an overlapping position. According to this configuration, the moving distance of the shutter member can be shortened, and opening and closing can be performed quickly.

More specifically, in the above-described configuration, the molten filament supply device is configured such that the plurality of nozzles are arranged in a horizontal direction including a first direction, and supply the molten filament group vertically downward. Of these nozzles, a nozzle that is within a predetermined range on the first direction end side may be the specific nozzle. According to this configuration, it is easy to adjust the filament density on the end side in the first direction of the molten filament group.

More specifically, in the above configuration, the molten filament supply device is configured such that the plurality of nozzles are arranged in a horizontal direction including the first direction which is the predetermined direction, and supplies the molten filament group vertically downward. Of the plurality of nozzles, the nozzles arranged in the direction orthogonal to the first direction on the first direction end side may be the specific nozzle.

More specifically, in the above-described configuration, the three-dimensional joined body forming apparatus is configured such that the first direction end portion of the molten filament group is brought into contact with a surface inclined with respect to the vertical direction so that the center side of the molten filament group is It is good also as a structure which has a receiving plate which guides to the said position and the said receiving plate is position-controlled in a 1st direction. According to this configuration, the position of the end portion in the first direction of the molten filament group can be adjusted.

More specifically, in the above-described configuration, the three-dimensional joined body forming apparatus is configured such that one end portion in the first direction of the molten filament group is brought into contact with a surface inclined with respect to the vertical direction. A first receiving plate that leads to the center side of the molten filament group, and a second receiver that leads the other end portion in the first direction of the molten filament group to a surface inclined with respect to the vertical direction and leads to the central side of the molten filament group A pair of receiving plates each having a plate, and the position of each of the pair of receiving plates may be controlled in the first direction. According to this configuration, it is possible to adjust the positions of both end portions in the first direction of the molten filament group.

Further, in the above-described configuration, the three-dimensional joined body forming apparatus includes a conveyor that is in contact with an end portion in the first direction of the molten filament group and is driven so as to convey the end portion to the downstream side. The position may be controlled in one direction. Further, in the above-described configuration, the three-dimensional joined body forming apparatus is in contact with one end portion in the first direction of the molten filament group, and is driven so as to convey the end portion to the downstream side, and the melt A pair of conveyors having a second conveyor in contact with the other end of the filament group in the first direction and driven to convey the end to the downstream side, and each of the pair of conveyors has a first direction It is good also as a structure by which position control is carried out. According to this structure, the position of a conveyor is adjusted according to the 1st direction dimension of a molten filament group, and suitable conveyance etc. of a molten filament group become easy.

The filament three-dimensional joined body manufacturing method according to the present invention discharges the molten filament vertically downward from a plurality of nozzles arranged in the horizontal direction including the first direction, and uses the discharged molten filament group to filament 3. A method for manufacturing a dimensional coupled body, comprising: a control step of controlling a position in the first direction of the end portion by opening and closing the nozzle corresponding to the end portion in the first direction of the melt filament group; By guiding the end in the first direction to the center side of the group of molten filaments, the position of the end in the first direction is regulated to a regulation position set to be changeable, and the molten filament in which the end is densified A densification step for generating a group, and a forming step for fusion-bonding the densified molten filament group to form a filament three-dimensional combination; Wherein said control step, in response to the restricting position, a method of controlling the first direction position of the first direction end portion of the molten filament group.

According to the filament three-dimensional joined body manufacturing apparatus or the filament three-dimensional joined body manufacturing method according to the present invention, it becomes easy to manufacture a filament three-dimensional joined body by adjusting the thickness and other dimensions and hardness.

It is a block diagram of the filament three-dimensional conjugate | bonded_body manufacturing apparatus which concerns on this embodiment. It is a cross-sectional arrow view of the filament three-dimensional joined body manufacturing apparatus shown in FIG. FIG. 5 is a configuration diagram in the vicinity of first to third units from a right viewpoint. FIG. 6 is a configuration diagram of another state in the vicinity of the first to third units from the right viewpoint. It is a block diagram of the 1st unit which concerns on 1st Embodiment. It is a block diagram of another state of the 1st unit which concerns on 1st Embodiment. It is explanatory drawing of the example which applied the filament three-dimensional coupling body to the mattress. It is a perspective view regarding the 1st structural example of the 2nd unit Z2. It is a perspective view regarding the 2nd structural example of the 2nd unit Z2. It is explanatory drawing regarding the position adjustment of a front side receiving plate member and a rear side receiving plate member. It is explanatory drawing regarding the 3rd structural example of 2nd unit Z2. It is explanatory drawing which shows the structure of each releasable cloth among the structures shown in FIG. It is explanatory drawing which shows structures other than each release fabric among the structures shown in FIG. It is a block diagram which shows the modification of 2nd unit Z2 and 3rd unit Z3. It is a block diagram of the 1st unit which concerns on 2nd Embodiment. It is a block diagram of the 1st unit which concerns on 3rd Embodiment. It is a cross-sectional arrow view of the 1st unit shown in FIG.

Embodiments of the present invention will be described below with reference to the drawings. In the following description, the top and bottom, left and right, and front and rear directions (directions orthogonal to each other) are as shown in the drawings. The downward direction coincides with the downward vertical direction, and the front-rear and left-right directions are included in the horizontal direction. The front-rear direction in the present embodiment is an example of the first direction according to the present invention.

1. First Embodiment First, a first embodiment of the present invention will be described. FIG. 1 is a schematic configuration diagram of a filament three-dimensional assembly manufacturing apparatus 1 according to the present embodiment. FIG. 2 is a cross-sectional view taken along the line AA ′ of the filament three-dimensional assembly manufacturing apparatus 1 shown in FIG. 3 and 4 are configuration diagrams in the vicinity of each unit (Z1 to Z3) included in the filament three-dimensional assembly manufacturing apparatus 1. FIG.

The filament three-dimensional joined body production apparatus 1 is an apparatus for producing a filament three-dimensional joined body 3 made of thermoplastic resin fibers having a three-dimensional network structure, and includes an extruder 10, a three-dimensional joined body forming apparatus 20, and the like. It has. In the following description, the thermoplastic resin fiber may be referred to as a filament, and the filament three-dimensional combination 3 may be referred to as FTS (Filament-linked Three-dimensional Structure) 3. Further, the filament three-dimensional joined body manufacturing apparatus 1 may be referred to as an FTS manufacturing apparatus 1.

The extrusion molding machine 10 is an example of a molten filament supply device that forms a filament (wire) in a molten state and discharges the filament toward the three-dimensional joined body forming device 20. The extrusion molding machine 10 includes an extruder 11 that is a pressure-melting section having a hopper 13 for material charging, a die 12 having a nozzle plate 17 connected to the extruder 11, and the like. The molten filament is discharged from 17. Hereinafter, the filament in a molten state may be referred to as a molten filament 2.

The hopper 13 is a material input unit for inputting a thermoplastic resin as a filament material into the extrusion molding machine 10. Examples of thermoplastic resins that can be used as the material for FTS3 include polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, polyamide resins such as nylon 66, polyvinyl chloride resins and polystyrene resins, Thermoplastic elastomers such as styrene elastomers, vinyl chloride elastomers, olefin elastomers, urethane elastomers, polyester elastomers, nitrile elastomers, polyamide elastomers, and fluorine elastomers can be used.

The extruder 11 is a pressure melting part that melts the thermoplastic resin while applying pressure. A cylinder 11 a is formed inside the extruder 11. A screw 14 rotated by a screw motor 15 is inserted through the cylinder 11a. A screw heater 16 is provided on the outer periphery of the cylinder 11a. The screw 14 is a pressurizing and conveying member that pressurizes and melts a thermoplastic resin that is heated and melted by the screw heater 16 and conveys the thermoplastic resin from the filament discharging portion 11b to the die 12. The screw heater 16 is a heating unit that heats the thermoplastic resin in the cylinder 11a.

The die 12 is a filament sending unit that sends the molten thermoplastic resin conveyed from the extruder 11 as a fibrous molten filament 2. A die guide channel 12 a is formed inside the die 12. The die heater 18 (18a to 18f) is a heating unit that heats the thermoplastic resin passing through the die guide channel 12a.

In the vicinity of the screw heater 16 and the die heater 18, a temperature sensor (not shown) for measuring the temperature of the thermoplastic resin is provided. Based on the temperature measurement results by these temperature sensors, the outputs of the screw heater 16 and the die heater 18 are controlled.

The extrusion molding machine 10 melts the thermoplastic resin supplied from the hopper 13 in the cylinder 11a and extrudes it downstream. The thermoplastic resin thus melted is discharged vertically downward as a plurality of molten filaments 2 from each nozzle 17a (see FIG. 5) formed on the nozzle plate 17 via the die guide passage 12a inside the die 12. Is done. In the following description, such a plurality of molten filaments 2 may be referred to as a molten filament group.

The nozzle plate 17 is a substantially rectangular parallelepiped (substantially rectangular parallelepiped having a front and rear, left and right, and upper and lower surfaces) in which a plurality of nozzles 17a that are circular holes penetrating in the vertical direction are formed. It is provided at the lower part of the die 12 corresponding to the most downstream part of the guide channel 12a. Each nozzle 17a is opened in the upper surface and lower surface of the nozzle plate 17, and can discharge the molten resin supplied from upper direction into a thread form downward.

The front-rear direction and the left-right dimension of the nozzle plate 17 can be set according to the cross-sectional dimensions (thickness dimension and width dimension of the mattress), for example, when manufacturing an FTS 3 for mattress. Since the nozzle plate 17 in the present embodiment is used for manufacturing, for example, an FTS 3 for a wide mattress, the lateral dimension (corresponding to the width dimension) is larger than the longitudinal dimension (corresponding to the thickness dimension). Yes.

On the nozzle plate 17, nozzles 17a are arranged in a matrix that is arranged two-dimensionally in the front-rear and left-right directions. The inner diameter of each nozzle 17a is set to be slightly smaller than the pitch (nozzle interval) between the nozzles 17a, but the specific form of the nozzle 17a is not particularly limited. For example, the inner diameter of each nozzle 17a may be set to 1 mm, and the pitch between the nozzles 17a may be set to 10 mm. In addition, the nozzle shape, nozzle inner diameter, nozzle interval, nozzle arrangement, and the like can be appropriately adjusted based on the specifications of the repulsive force of the FTS 3.

The three-dimensional joined body forming apparatus 20 forms a three-dimensional network FTS 3 by fusion bonding and cooling and solidifying a plurality of molten filaments 2. The three-dimensional combined body forming apparatus 20 includes a receiving plate 21 (a pair of front and rear receiving plates 21a and 21b) and cooling water 22a installed so as to be plane-symmetrical with a predetermined interval. And a cooler 22 including a water tank 23 for storing water.

The front receiving plate 21a includes a flat plate-like inclined surface 21a1 (surface inclined with respect to the vertical direction) inclined downward and a flat plate-like vertical surface 21a2 extending vertically downward from the lower portion of the inclined surface 21a1. . These surfaces 21a1 and 21a2 are formed by bending a metal plate material. The rear receiving plate 21b includes a flat plate-like inclined surface 21b1 (a surface inclined with respect to the vertical direction) inclined downward and a flat plate-like vertical surface 21b2 extending vertically downward from the lower portion of the inclined surface 21b1. Including. These surfaces 21b1 and 21b2 are formed by bending a metal plate material.

Each molten filament 2 discharged from the nozzle plate 17 translates vertically downward with the help of gravity, and reaches each receiving plate 21 disposed below the nozzle plate 17. At this time, the molten filament 2 located near the center in the front-rear direction of the molten filament group directly enters the gap between the vertical surfaces 21a2 and 21b2 of the receiving plates 21.

On the other hand, the molten filament 2 located near the front end of the molten filament group contacts the inclined surface 21a1 of the front receiving plate 21a, and then enters the vicinity of the front end of the gap along the inclined surface 21a1. In addition, the molten filament 2 located near the rear end of the molten filament group contacts the inclined surface 21b1 of the rear receiving plate 21b, and then enters the vicinity of the rear end of the gap along the inclined surface 21b1.

By means of the pair of front and rear receiving plates 21, both ends (surface layers) in the front-rear direction of the molten filament group are moved toward the center to increase the density, and hard surface layers can be formed at both ends. By forming the hard surface layer, changes in the thickness (front-rear direction dimension) of the FTS 3 in the transport direction can be suppressed, and the shape of the FTS 3 can be stabilized.

A cooling water supply device (not shown) for supplying cooling water to the entire surface of each receiving plate 21 may be provided on the upper portion of each receiving plate 21. By suppressing or preventing the temperature rise of each backing plate 21 by supplying cooling water, it is possible to prevent the molten filament 2 from being fused to each backing plate 21. The molten filament 2 that has entered the gap sandwiched between the vertical surfaces 21a2 and 21b2 of the receiving plates 21 further proceeds to the cooler 22 below.

Each receiving plate 21 can receive and temporarily retain the molten filament 2 by the buoyancy action of the cooling water 22a in the water tank 23, and promotes fusion bonding between the retained molten filaments 2. That is, since the molten filament 2 receives the buoyancy of the cooling water 22a inside each receiving plate 21, and the conveying speed (take-off speed) of the conveyor described later is set slower than the falling speed of the molten filament 2, It stays inside the receiving plate 21. At this time, fusion bonding between the molten filaments 2 can be further advanced.

The cooler 22 cools and solidifies the melted filament 2 that has been fusion bonded. The cooler 22 includes a water tank 23 that stores cooling water 22a, conveyors that transport the FTS 3 (a pair of front and rear conveyors 24a and 24b), a plurality of transport rollers 25a to 25h, and these conveyors. And a conveyance motor (not shown) for driving the conveyance roller via a gear.

Each conveyor 24 and the plurality of transport rollers 25a to 25h are transport devices that transport the FTS 3. Each conveyor 24 is formed in an endless shape, and is provided in a vertically lower portion of each receiving plate 21. By rotating each conveyor 24, a group of mesh-like molten filaments in which fusion bonding is advanced three-dimensionally can be conveyed downward while being cooled with cooling water 22a. The front conveyor 24a is in contact with the front end portion of the molten filament group, and is driven so as to convey the front end portion to the downstream side (taken to the downstream side). The rear conveyor 24b is in contact with the rear end portion of the molten filament group and is driven so as to convey the rear end portion to the downstream side (taken to the downstream side).

The conveyance speed of each conveyor 24 is closely related to the filament density. That is, in relation to the cooling speed of the molten filament 2, the filament density decreases as the conveying speed increases, and the filament density increases as it decreases. The transport rollers 25a to 25h are disposed at the subsequent stage of each conveyor 24, and transport the FTS 3 that has passed through each conveyor 24 to the outside of the water tank 23. Each of the transport rollers 25a to 25h is rotatably supported by a support member (not shown) and urged in a direction to compress the FTS 3 by a spring (not shown) so as to obtain a predetermined frictional force with the FTS 3. It is supposed to be.

In this embodiment, a belt conveyor made of a net-like metal mesh is adopted as each conveyor 24. However, the present invention is not limited to this, and various types of conveying devices can be adopted. For example, a slat conveyor or the like can be adopted as the transfer device.

Further, the FTS manufacturing apparatus 1 is provided with a first unit Z1 including a nozzle plate 17, a second unit Z2 including each receiving plate 21, and a third unit Z3 including each conveyor 24 as units having a drive mechanism. Yes. Hereinafter, each of these units will be described.

5 and 6 are schematic configuration diagrams of the first unit Z1 from the upper viewpoint. 3 and 5 show an example of a state in which each shutter plate 32 does not close any of the nozzles 17a (a state in which all the nozzles 17a are open). FIG. 4 and FIG. An example of a state in which the shutter plate 32 closes a specific nozzle (a nozzle that can be opened and closed) is shown.

As shown in FIG. 3 and the like, the first unit Z1 includes the nozzle plate 17, the shutter plates 32 (the front shutter plate 32a and the rear shutter plate 32b) disposed on the nozzle plate 17, and the shutters. Each shutter plate driving unit 33 (front shutter plate driving unit 33a and rear shutter plate driving unit 33b) for driving the plate 32 is provided.

Each shutter plate 32 is a metal plate having a thickness in the range of 3 mm to 20 mm, and is movably disposed along the upper surface of the nozzle plate 17 in the horizontal direction (more specifically, in the front-rear direction). Each shutter plate 32 is movable so as to open and close a predetermined nozzle 17 a (specific nozzle) while discharging the molten filament 2 from the extrusion molding machine 10. The front shutter plate 32 a is movable in the front-rear direction in a front region of the upper surface of the nozzle plate 17. On the other hand, the rear shutter plate 32 b is movable in the front-rear direction in the rear region of the upper surface of the nozzle plate 17. When each shutter plate 32 moves to a position that closes the upper side of the nozzle 17a, the nozzle 17a is in a closed state. The molten filament 2 is not discharged from the closed nozzle 17a. By opening / closing the nozzle 17a, whether or not the molten filament 2 is discharged from the nozzle 17a is switched.

Each shutter plate drive unit 33 moves each shutter plate 32 in the front-rear direction. Each shutter plate driving unit 33 can independently move the front shutter plate 32a and the rear shutter plate 32b.

In the present embodiment, each nozzle 17a (each nozzle 17a within a predetermined range on the front end side) for Xa rows (for example, 4 rows) from the front is a specific nozzle that is opened and closed by the front shutter plate 32a. Each nozzle 17a (each nozzle 17a within a predetermined range on the rear end side) corresponding to Xb rows (for example, 4 rows) is a specific nozzle that is opened and closed by the rear shutter plate 32b. However, which nozzle 17a is used as the specific nozzle can be arbitrarily set within a range not departing from the gist of the present invention.

The front shutter plate drive unit 33a is disposed in the vicinity of the front edge of the nozzle plate 17, and pushes the front shutter plate 32a backward or pulls it forward to move it in the front-rear direction. Thereby, the state of the front shutter plate 32a is a state where none of the nozzles 17a is blocked, a state where the nozzles 17a from the front to the first row are closed, and a state where the nozzles 17a from the front to the Xa row are blocked. It is possible to switch between the states including.

The rear shutter plate drive unit 33b is disposed in the vicinity of the rear edge of the nozzle plate 17, and moves the rear shutter plate 32b forward and backward to move in the front-rear direction. As a result, the state of the rear shutter plate 32b is such that none of the nozzles 17a is blocked, the state where the nozzles 17a from the rear to the first row are blocked,..., And the nozzles 17a from the rear to the Xb rows are blocked. It is possible to switch between the states including the state.

As described above, each shutter plate 32 is movable between an open position where the opening of the specific nozzle is opened (a position where the upper side of the specific nozzle is not blocked) and a closed position where the opening is closed (a position where the upper side of the specific nozzle is closed). Yes, it can be used to open and close specific nozzles. In the present embodiment, each shutter plate 32 is provided so as to slide on the upper surface of the nozzle plate 17, but each shutter plate 32 may be provided so as to slide on the lower surface of the nozzle plate 17. In any case, each shutter plate 32 is movable between the open position and the closed position so as to slide on the surface of the nozzle plate 17 (the surface including the opening of the specific nozzle), and thus has a relatively simple configuration. However, it is possible to accurately open and close the specific nozzle.

As shown in FIGS. 3 and 4, the position in the front-rear direction of the rear end of the front shutter plate 32a (hereinafter sometimes referred to as “position P1” for the sake of convenience) shifts more rearward in order. Since the specific nozzle is closed, the position of the front end portion of the molten filament group becomes the rear side. The position P1 can be changed by the movement of the front shutter plate 32a described above. By the same principle, the front-rear direction position of the front end portion of the rear shutter plate 32b (hereinafter sometimes referred to as “position P2” for convenience) can be changed by the movement of the rear shutter plate 32b. As shown in FIGS. 3 and 4, as the position P2 moves forward, more specific nozzles are blocked later in order, so that the position of the rear end portion of the molten filament group becomes the front side.

In the second unit Z2, the receiving plates 21, the receiving plate support portions 42 (the front receiving plate support portion 42a and the rear receiving plate support portion 42b) extending in the front-rear direction, and the receiving plates 21 are horizontally disposed. Each receiving plate driving section 43 (front receiving plate driving section 43a and rear receiving plate driving section 43b) that moves in the direction (more specifically, the front-rear direction) is provided.

More specifically, the front receiving plate support portion 42a has a front receiving plate 21a fixed to the rear end side, and the front end side is connected to the front receiving plate driving portion 43a. The front receiving plate driving unit 43a can move the front receiving plate 21a in the front-rear direction via the front receiving plate support 42a.

The rear receiving plate support portion 42b has a rear receiving plate 21b fixed to the front end side, and a rear end side connected to the rear receiving plate driving portion 43b. The rear receiving plate driving unit 43b can move the rear receiving plate 21b in the front-rear direction via the rear receiving plate support 42b. With the above-described mechanism, the front receiving plate 21a and the rear receiving plate 21b are supported separately and are movable in the front-rear direction independently of each other.

The front receiving plate 21a guides the front end of the molten filament group to the inclined surface 21a1 and slides the inclined surface 21a1 backward (the center side of the molten filament group). Accordingly, the front receiving plate 21a has a role of densifying the front end portion of the molten filament group and restricting the front end portion to a restricting position (position of the vertical surface 21a2) set to be changeable. Also fulfills. That is, the front-rear direction position of the front end portion of the molten filament group that has reached the front receiving plate 21a is the front-rear direction position of the vertical surface 21a2 of the front receiving plate 21a (hereinafter, for convenience). (Sometimes referred to as “position P3”). The position P3 can be changed by moving the front receiving plate 21a in the front-rear direction.

Further, the degree of densification of the front end portion of the molten filament group increases as the amount of the molten filament 2 guided backward by the inclined surface 21a1 increases, and thus increases as the distance from the position P1 to the position P3 increases. Become. Therefore, the position P1 is adjusted so that the front end of the molten filament group is densified to a desired degree after adjusting the position P3 so that the front-rear direction position of the front end of the molten filament group becomes a desired position. Can be adjusted.

The rear receiving plate 21b is guided forward (to the center side of the molten filament group) so that the rear end of the molten filament group is in contact with the inclined surface 21b1 and the inclined surface 21b1 is slid. As a result, the rear receiving plate 21b increases the density of the rear end of the molten filament group, and at the restriction position (position of the vertical surface 21b2) set so that the position of the rear end in the front-rear direction can be changed. It also plays a regulatory role. That is, the front-rear direction position of the rear end portion of the molten filament group that has reached the rear receiving plate 21b is the front-rear direction position (hereinafter referred to as the vertical surface 21b2) of the rear receiving plate 21b, as shown in FIGS. For convenience, it may be referred to as “position P4”). The position P4 can be changed by moving the rear receiving plate 21b in the front-rear direction.

In addition, the degree of density increase in the density of the rear end portion of the molten filament group increases as the amount of the molten filament 2 guided forward by the inclined surface 21b1 increases. Therefore, the distance from the position P2 to the position P4 increases. Get higher. Therefore, after adjusting the position P4 so that the position in the front-rear direction of the rear end of the molten filament group is a desired position, the density of the rear end of the molten filament group is increased to a desired degree. It is possible to adjust the position P2.

3rd unit Z3 is comprised so that each conveyor 24 mentioned above may be supported movably in the front-back direction. More specifically, on the inner side of the endless front conveyor 24a, the front drive roller 52a is disposed on the upper side, and the front driven roller 53a is disposed on the lower side. The front conveyor 24a is stretched around these rollers (52a, 53a) and is rotatably supported. When the front drive roller 52a is driven to rotate, the front conveyor 24a is also rotated accordingly, and the molten filament 2 that is in contact with the rear outer surface of the front conveyor 24a is conveyed downward.

The rotation shaft 54a of the front drive roller 52a is rotatably attached to the rear end side of the front upper conveyor support portion 56a extending in the front-rear direction. The front end side of the front upper conveyor support part 56a is connected to the front upper conveyor drive part 58a. The front upper conveyor drive unit 58a moves the front drive roller 52a in the front-rear direction via the front upper conveyor support unit 56a.

The rotation shaft 55a of the front driven roller 53a is rotatably attached to the rear end side of the front lower conveyor support portion 57a extending in the front-rear direction. The front end side of the front lower conveyor support part 57a is connected to the front lower conveyor drive part 59a. The front lower conveyor drive part 59a moves the front driven roller 53a in the front-rear direction via the front lower conveyor support part 57a.

Note that the amount of movement and the movement speed of the front drive roller 52a and the front driven roller 53a in the front-rear direction are set so that the positions of the rollers 52a, 53a are always the same. Accordingly, the front conveyor 24a can be moved in the front-rear direction while the rear outer surface of the front conveyor 24a is always kept vertical and the molten filament 2 can be appropriately conveyed downward. Alternatively, the front upper conveyor support portion 56a and the front lower conveyor support portion 57a may be integrated and driven by the same driving device.

Further, inside the endless rear conveyor 24b, a rear drive roller 52b is disposed on the upper side, and a rear driven roller 53b is disposed on the lower side. The rear conveyor 24b is stretched around these rollers (52b, 53b) and is rotatably supported. When the rear drive roller 52b is rotationally driven, the rear conveyor 24b is also rotated accordingly, and the molten filament 2 in contact with the outer surface on the front side of the rear conveyor 24b is conveyed downward.

The rotating shaft 54b of the rear drive roller 52b is rotatably attached to the front end side of the rear upper conveyor support 56b that extends in the front-rear direction. The rear end side of the rear upper conveyor support part 56b is connected to the rear upper conveyor drive part 58b. The rear upper conveyor drive unit 58b moves the rear drive roller 52b in the front-rear direction via the rear upper conveyor support unit 56b. The front drive roller 52a and the rear drive roller 52b are set to rotate at the same speed in opposite rotation directions so that the conveyor 24 appropriately conveys the molten filament 2.

The rotation shaft 55b of the rear driven roller 53b is rotatably attached to the front end side of the rear lower conveyor support portion 57b extending in the front-rear direction. The rear end side of the rear lower conveyor support part 57b is connected to the rear lower conveyor drive part 59b. The rear lower conveyor driving portion 59b moves the rear driven roller 53b in the front-rear direction via the rear lower conveyor support portion 57b.

Note that the amount of movement and the movement speed of the rear drive roller 52b and the rear driven roller 53b in the front-rear direction are set so that the front-rear direction positions of these rollers 52b, 53b are always the same. Accordingly, the rear conveyor 24b can be moved in the front-rear direction while the front outer surface of the rear conveyor 24b is always kept vertical and the molten filament 2 can be appropriately conveyed downward. Alternatively, the rear upper conveyor support portion 56b and the rear lower conveyor support portion 57b may be integrated and driven by the same driving device. With the above mechanism, the front conveyor 24a and the rear conveyor 24b are separately supported and are movable in the front-rear direction independently of each other.

Next, the control system and control method for controlling the drive mechanism of each unit (Z1 to Z3) will be described. As a component of the control system in the FTS manufacturing apparatus 1, a thickness direction position control unit 30, a shutter plate control unit 34, a receiving plate control unit 35, and a conveyor control unit 36 are provided as shown in the block of FIG. Yes.

The thickness direction position control unit 30 receives input of conditions for manufacturing the FTS 3 in a desired state, that is, information such as the shape in the thickness direction of the FTS 3 and the degree of densification at both ends in the thickness direction. In response to this, the thickness direction position control unit 30 moves the front and rear positions of the shutter plates 32, the receiving plates 21 and the conveyors 24 (to the thickness direction position of the FTS 3 so that the FTS 3 satisfying the condition is manufactured. Control).

More specifically, the thickness direction position control unit 30 sends a signal for controlling the position (position P1 and position P2) of each shutter plate 32 to the shutter plate control unit 34, and the position ( Signals for controlling the positions P3 and P4) are sent to the plate control unit 35, and signals for controlling the position of each conveyor 24 are sent to the conveyor control unit 36.

Upon receiving the signal, the shutter plate control unit 34 sends a drive control signal to each shutter plate drive unit 33 to drive each shutter plate 32. Further, the backing plate control unit 35 sends a driving control signal to each backing plate drive unit 43 so as to drive each backing plate 21. Moreover, the conveyor control part 36 sends a drive control signal to each conveyor drive part (58a, 58b, 59a, 59b), and drives each conveyor 24. FIG. The thickness direction position control unit 30 may also serve as the shutter plate control unit 34, the receiving plate control unit 35, and the conveyor control unit 36.

The shape of the end portion in the thickness direction of the FTS 3 is generally determined by the position P3 for one end and is generally determined by the position P4 for the other end. Therefore, the thickness direction position control unit 30 controls the positions P3 and P4 so that both end portions in the thickness direction of the FTS 3 have a desired shape. The thickness of the FTS 3 is generally determined by the distance between the position P3 and the position P4 (the size of the gap between the receiving plates 21). Therefore, when the thickness of the FTS 3 is determined in advance, the position of each receiving plate 21 may be controlled so that the distance between the position P3 and the position P4 matches the thickness.

Further, the thickness direction position control unit 30 controls the positions P1 and P2 so that both ends of the FTS 3 are densified at a desired degree. That is, according to the degree, the distance between the position P1 and the position P3 and the distance between the position P2 and the position P3 are adjusted. As described above, the greater the distance between the position P1 and the position P3, the higher the degree of densification at the front end of the FTS 3, and the greater the distance between the position P2 and the position P4, the rear end of the FTS 3. The degree of densification increases.

Further, the thickness direction position control unit 30 controls the position in the front-rear direction of each conveyor 24 so that the molten filament group receives an appropriate compressive force (friction force) from each conveyor 24 based on the distance between the positions P3 and P4. To do. For example, the front-rear direction position of the front conveyor 24a is controlled to a position substantially equivalent to the position P3, and the front-rear direction position of the rear conveyor 24b is controlled to a position substantially equivalent to the position P4. In addition, by making the gap between the conveyors 24 smaller than the distance between the position P1 and the position P2 or the distance between the position P3 and the position P4, the filament density (compressibility) at both ends in the front-rear direction of the molten filament group is reduced. May be high.

In addition, the specific method of the position control by the thickness direction position control unit 30 is not limited to the above-described method, and different methods can be adopted depending on various circumstances. Further, according to the product specifications of the FTS 3, etc., only one of the front side and the rear side is provided for all or part of each shutter plate 32, each receiving plate 21 and each conveyor 24 that are provided in pairs. It may be movable in the front-rear direction (the other position is fixed).

Further, the above-described position control can be performed while continuously discharging the molten filament 2 from the nozzle plate 17, and it is possible to form the FTS 3 whose thickness changes in the transport direction. Furthermore, in this embodiment, it is possible to increase the density of both ends in the thickness direction of the FTS 3 to a desired degree by opening and closing the specific nozzle using each shutter plate 32. It can be formed properly.

The FTS 3 formed so that the thickness changes in the conveyance direction can be applied to various uses. FIG. 7 shows an example in which such FTS 3 is applied to various types of mattresses. Note that the transport direction of the FTS 3 in this example corresponds to the length direction of the mattress (the direction connecting the top of the user lying on the mattress and the feet). The vertical direction in FIG. 7 is the thickness direction of the mattress, and the user lies on the upper side of the mattress. Further, the hardness of each FTS 3 (3a to 3i) shown in FIG. 7 is adjusted by the filament density, and the harder FTS is manufactured such that the filament density becomes higher.

FIG. 7A is a conceptual diagram showing the shape of the mattress whose thickness changes in the length direction and the state in which the user is using it. In this example, an FTS 3a having a lower surface as a plane and an upper surface as a wave shape is used. Thereby, the surface shape of the upper side of the mattress is changed in the length direction so that the position of the head and knee of the user lying on the back on the mattress is higher than the positions of the waist and the feet.

FIG. 7B is a conceptual diagram showing the shape of a mattress in which a soft FTS 3c is stacked on a hard FTS 3b and a state in which the user is using the mattress. In this example, the wave shapes provided at the joint portions of the FTS 3b and the FTS 3c are formed so as to fit in a state where they are overlapped. This wave shape suppresses misalignment between the FTSs and adjusts the hardness of the mattress in the length direction. That is, the wave shape is adjusted so that the ratio of the harder FTS 3b in the thickness direction is higher in the mattress to be hardened. Further, by adopting a gentle wave shape, the mattress can be prevented from becoming locally hard.

FIG. 7C is a conceptual diagram showing the shape of a mattress in which a hard FTS 3e is stacked on a soft FTS 3d, and a state in which the user is using the mattress. In this example, the wave shapes provided at the joint portions of the FTS 3d and the FTS 3e are formed so as to fit in a state where they are overlapped. Similar to the case of FIG. 7B, this wave shape suppresses misalignment between FTSs and adjusts the hardness of the mattress in the length direction.

FIG. 7D shows a mattress shape in which three FTSs (soft FTS 3g, hard FTS 3h, and slightly soft FTS 3i) are stacked on a standard FTS 3f. It is a conceptual diagram which shows the state currently used. In this example, the wave shapes provided at the joint portions of the upper and lower FTSs are formed so as to fit in a state where they are overlapped. Moreover, the hardness of the mattress is adjusted in the length direction by disposing a plurality of FTSs having different hardnesses in the length direction. By making the joint portion of the upper and lower FTS into a gentle wave shape, it is possible to prevent the mattress from becoming locally hard, and even when a plurality of FTSs 3 are arranged in the horizontal direction, these positions are arranged. It is possible to prevent deviation as much as possible.

In general, in order to obtain an FTS whose thickness varies in the length direction, it is necessary to superimpose two or more FTSs so as to obtain a desired thickness, or to cut the surface. Cost increases. In this regard, according to the FTS manufacturing apparatus 1 of the present embodiment, the thickness can be changed in the length direction (conveyance direction) in the process of forming the FTS, and the processing is omitted or simplified to suppress the manufacturing cost. Is possible.

As described above, the FTS manufacturing apparatus 1 has the FTS 3 by fusion-bonding the extruder 10 (molten filament supply apparatus) that discharges the molten filament 2 from each of the plurality of nozzles 17a and the discharged molten filament group. And a three-dimensional combined body forming apparatus 20 for forming the structure. Furthermore, the extrusion molding machine 10 has a functional part (opening / closing part) that opens and closes a specific nozzle that is at least one of the plurality of nozzles 17a.

For this reason, it is easy to more appropriately form the FTS 3 in which the thickness and the like of the FTS 3 are increased in density in a desired degree by opening and closing the specific nozzle, and the thickness and the like change in the transport direction. Further, the switching of whether or not the molten filament 2 is discharged by opening and closing the specific nozzle can be used to adjust the hardness (filament density) of the entire FTS 3 or an arbitrary portion.

As an example, when the overall hardness of the FTS 3 can be adjusted as appropriate, specific nozzles that can be switched between open and close are provided uniformly in the plurality of nozzles 17a, and a large amount of FTS 3 is produced when manufacturing an overall hard FTS 3. When the specific nozzles are in the open state and the FTS 3 that is soft overall is manufactured, many specific nozzles may be in the closed state. As a result, when many specific nozzles are opened, the filament density can be increased overall to produce a harder FTS3. When many specific nozzles are closed, the filament density is increased as a whole. Therefore, it is possible to manufacture a soft FTS 3 at a low level. As described above, since the specific nozzle can be opened and closed, it is easy to manufacture the FTS 3 by adjusting the thickness dimension, hardness, and the like.

Further, in the method for manufacturing the FTS 3 according to the present embodiment, the molten filament 2 is discharged vertically downward from the plurality of nozzles 17a arranged in the horizontal direction including the front-rear direction, and the FTS 3 is discharged using the discharged molten filament group. It is a manufacturing method. The method includes a control step, a densification step, and a formation step.

The control step is a step (process) of controlling the position of the end portion in the front-rear direction by opening and closing the nozzle 17a corresponding to the end portion in the front-rear direction of the molten filament group. The densification step regulates the front-rear direction end of the molten filament group to the center side of the molten filament group, thereby regulating the front-rear direction position of the end to a restriction position set to be changeable. Is a step of generating a high density densified molten filament group. The forming step is a step of forming the FTS 3 by fusion-bonding the densified molten filament group.

And the said control step is a step which controls the front-back direction position of the front-back direction edge part of a molten filament group according to the said control position. Thereby, the filament density in the front-back direction edge part of a molten filament group can be adjusted. If the distance between the first position and the third position described above or the distance between the second position and the fourth position is controlled so as to maintain a constant value, the change in the filament density is suppressed and the change in the surface smoothness is reduced. It can be made.

In addition, various forms can be adopted as a specific configuration of the second unit Z2 (see FIG. 3 and the like) in the present embodiment. FIG. 8 shows a part of the configuration example (first configuration example) of the second unit Z2 (the front receiving plate 21a, the front receiving plate support portion 42a, the rear receiving plate 21b, and the rear receiving plate support portion 42b). The perspective view of the part) is shown.

In the second unit Z2 shown in FIG. 8, the front receiving plate support portion 42a is composed of six support rods 42a1 to 42a6, and supports the front receiving plate 21a so that it can move in the horizontal direction (front-rear direction). ing. More specifically, each of the support bars 42a1 to 42a6 has a bar shape extending in the front-rear direction, and is arranged at substantially equal intervals in the left-right direction. The rear receiving plate support portion 42b is composed of six support rods 42b1 to 42b6, and supports the rear receiving plate 21a so that it can move in the horizontal direction (front-rear direction). More specifically, each of the support bars 42b1 to 42b6 has a bar shape extending in the front-rear direction, and is arranged at substantially equal intervals in the left-right direction. According to the configuration shown in FIG. 8, the front receiving plate 21a and the rear receiving plate 21a can be supported efficiently by a relatively small number of members while being movable in the front-rear direction.

FIG. 9 shows another configuration example (second configuration example) of the second unit Z2 (a front receiving plate 21a, a front receiving plate support portion 42a, a rear receiving plate 21b, and a rear receiving plate support portion). 42b) is a perspective view. In the second unit Z2 shown in FIG. 9, the front receiving plate 21a is composed of a plurality (25 in this embodiment) of front receiving plates 121a1 to 121a25. The plurality of front receiving plate members 121a1 to 121a25 are arranged in order in the left-right direction, and function as the front receiving plate 21a as a whole. The plurality of front receiving plate members 121a1 to 121a25 are supported by the support rods 142a1 to 142a25 (corresponding to the front receiving plate support portion 42a) so as to be independently movable in the horizontal direction (front-rear direction). ing. As a result, as shown in FIG. 10, it is easy to adjust the front-rear direction position of each of the front receiving plate members 121a1 to 121a25 and to optimize the shape of the front receiving plate 21a.

The rear side receiving plate 121b includes a plurality (25 in this embodiment) of the rear side receiving plates 121b1 to 121b25. Several rear receiving plate members 121b1 to 121b25 are arranged in order in the left-right direction, and play the role of the rear receiving plate 21b as a whole. The plurality of rear receiving plates 121b1 to 121b25 are supported by the support rods 142b1 to 142b25 (corresponding to the rear receiving plate support portion 42b) so that they can be moved independently in the horizontal direction (front-rear direction). Has been. As a result, as shown in FIG. 10, it is easy to adjust the position of each of the rear receiving plate members 121b1 to 121b25 in the front-rear direction to optimize the shape of the rear receiving plate 21b. The filament three-dimensional assembly manufacturing apparatus 1 may be provided with a cooling water supply device (not shown) for supplying cooling water to the entire surfaces of the front receiving plate members 121a1 to 121a25 and the rear receiving plate members 121b1 to 121b25. .

FIG. 11 shows a part of the second unit Z2 (third configuration example) (a front receiving plate 21a, a front receiving plate support portion 42a, a rear receiving plate 21b, and a rear receiving plate support). The perspective view of the part 42b) is shown. FIG. 12 is a diagram showing the configuration of the releasable fabrics 221aa and 221bb among the configurations shown in FIG. Furthermore, FIG. 13 is a diagram showing a configuration other than the releasable fabrics 221aa and 221bb among the configurations shown in FIG.

The front receiving plate 21a in the third configuration example includes a plurality of (25 in this embodiment) front receiving plate members 221a1 to 221a25 and a deformable releasability covering the outer periphery of the front receiving plate members 221a1 to 221a25. It is comprised by the fabric 221aa. The plurality of front receiving plate members 221a1 to 221a25 are arranged in order in the left-right direction, and are each independently supported in the horizontal direction (front and back) by support rods 242a1 to 242a25 (corresponding to the front receiving plate support portion 42a). It is supported so that it can move in the direction). Accordingly, it is easy to adjust the front and rear direction positions of the front receiving plate members 221a1 to 221a25 and to optimize the shape of the front receiving plate 21a.

Even when the front receiving plate members 221a1 to 221a25 are independently moved in the horizontal direction and a step is generated between the front receiving plate members 221a1 to 221a25, the releasable fabric 221aa deforms to cause the deformation. The level difference (unevenness) becomes smooth. Therefore, the densified surface layer at the front end portion of the molten filament group can be formed as a smooth surface layer without steps.

Further, the rear receiving plate 221b includes a plurality (25 in this embodiment) of the rear receiving plate members 221b1 to 221b25 and a deformable releasability covering the outer periphery of the rear receiving plate members 221b1 to 221b25. It is comprised by the fabric 221bb. The plurality of rear receiving plate members 221b1 to 221b25 are arranged in order in the left-right direction, and are each independently supported by the supporting rods 242b1 to 242b25 (corresponding to the rear receiving plate support portion 42b) in the horizontal direction. It is supported so that it can move in the (front-rear direction). Accordingly, it is easy to adjust the position of the rear receiving plate members 221b1 to 221b25 in the front-rear direction and to optimize the shape of the rear receiving plate 21b.

Even if the rear receiving plate members 221b1 to 221b25 move independently in the horizontal direction and a step is generated between the rear receiving plate members 221b1 to 221b25, the releasable fabric 221bb is deformed. As a result, the step (irregularity) becomes smooth. Therefore, the densified surface layer at the rear end of the molten filament group can be formed as a smooth surface layer without a step.

As each of the releasable fabrics 221aa and 221bb, it is desirable to use a fabric that does not melt the melt filament and can be deformed. For example, a deformable fabric knitted with fluororesin fibers can be used. Thereby, it becomes possible to prevent fusion of the molten filament to each of the releasable fabrics 221aa and 221bb. Further, as each of the releasable fabrics 221aa and 221bb, for example, a water-absorbent fabric in which a water-absorbent yarn including cotton fibers having a high water-absorbing function is knitted into a knit shape to be deformable may be used. Further, such a water absorbent fabric is used, and a cooling water supply device (not shown) or the like is provided in the filament three-dimensional joined body manufacturing apparatus 1 so that the cooling water is supplied to the entire surface of the water absorbent fabric. Anyway. Thereby, fusion | melting of a molten filament and a temperature rise can be prevented.

FIG. 14 is a configuration diagram showing a modification of the second unit Z2 and the third unit Z3 shown in FIG. In this modification, the function of the second unit Z2 is performed by the third unit Z3, and the installation of the second unit Z2 is omitted. More specifically, the third unit Z3 in this modification has a front conveyor 22a and a rear conveyor 22b which are a pair of front and rear.

The front conveyor 22a has a driven roller 81a, a driving roller 82a provided below the driving roller 81a, a pressure roller 83a provided between these rollers, and a stretched support rotatably by the driven roller 81a and the driving roller 82a. Heat resistant belt 80a.

Further, as shown in FIG. 14, the rotation shafts of the rollers 81a, 82a, 83a are rotatably attached to the rear end sides of the conveyor support portions 84a, 85a, 86a extending in the front-rear direction. The front end side of each conveyor support part 84a, 85a, 86a is connected to each of the conveyor drive parts 87a, 88a, 89a. Each conveyor drive part 87a, 88a, 89a can move a corresponding roller to the front-back direction via a corresponding conveyor support part.

The moving amount and moving speed of each roller 81a, 82a, 83a in the front-rear direction are set so that the front-rear direction position of these rollers is always the same. Accordingly, the front conveyor 22a can be moved in the front-rear direction while the rear outer surface of the front conveyor 22a is always kept vertical and the molten filament 2 can be appropriately conveyed downward. In addition, each conveyor support part 84a, 85a, 86a may be integrated, and you may make it move this with the same drive device.

The rear conveyor 22b includes a driven roller 81b, a driving roller 82b provided below the driven roller 81b, a pressure roller 83b provided between these rollers, and a rotatable roller 81b and the driving roller 82b. And a heat-resistant belt 80b to be supported.

As shown in FIG. 14, the rotation shafts of the rollers 81b, 82b, and 83b are rotatably attached to the front end sides of the conveyor support portions 84b, 85b, and 86b extending in the front-rear direction. The rear end side of each conveyor support part 84b, 85b, 86b is connected to the conveyor drive part 87b, 88b, 89b, respectively. Each conveyor drive part 87b, 88b, 89b can move a corresponding roller to the front-back direction via a corresponding conveyor support part.

The amount and speed of movement of each roller 81b, 82b, 83b in the front-rear direction are set so that the front-rear direction positions of these rollers are always the same. Thus, the rear conveyor 22b can be moved in the front-rear direction while the rear outer surface of the rear conveyor 22b is always kept vertical and the molten filament 2 can be appropriately conveyed downward. In addition, each conveyor support part 84b, 85b, 86b may be integrated, and you may make it move this with the same drive device.

By the mechanism of the modification, the front conveyor 24a and the rear conveyor 24b are supported separately and are movable in the front-rear direction independently of each other. A part of each heat-resistant belt 80a, 80b supported by the front and rear driven rollers 81a, 81b plays a role of the receiving plate 21 in the first embodiment. Each drive roller 81a, 81b is rotationally driven in the direction indicated by the arrow in FIG. 14 so that the molten filament 2 sandwiched between each heat-resistant belt 80a, 80b is conveyed downward.

2. Second Embodiment Next, a second embodiment of the present invention will be described. The second embodiment is basically the same as the first embodiment except for the point relating to the first unit. In the following description, emphasis is placed on the description of contents different from the first embodiment, and description of contents common to the first embodiment may be omitted.

FIG. 15 is a schematic configuration diagram from an upper viewpoint of the first unit Z1a according to the second embodiment. As shown in the figure, the first unit Z1a includes the nozzle plate 17, the shutter plates 132 (the front shutter plates 132 and the rear shutter plates 132b) disposed on the nozzle plate 17, and the shutter plates 132. Each of the shutter plate driving units 133 (the front shutter plate driving unit 133a and the rear shutter plate driving unit 133b). Here, “n” represents the number of nozzles 17a arranged in a matrix in the front, rear, left, and right directions, and the configuration of the nozzle plate 17 is basically the same as that of the nozzle plate 17 of the first embodiment. is there.

Each shutter plate 132 is a metal plate having a thickness in the range of 3 mm to 20 mm, and is movably disposed in the front-rear direction along the upper surface of the nozzle plate 17 (the surface including the opening of each nozzle 17a). Each shutter plate 132 is movable so as to open and close a predetermined nozzle 17 a (specific nozzle) while discharging the molten filament 2 from the extrusion molding machine 10. Each shutter plate 132 has a plate shape extending in the front-rear direction, and the width in the left-right direction is substantially equal to the pitch in the left-right direction of each nozzle 17a.

Each of the front shutter plates 132a (132a1 to 132an) is movable in the front-rear direction in the front region of the upper surface of the nozzle plate 17. On the other hand, each of the rear shutter plates 132b (132b1 to 132bn) is movable in the front-rear direction in the rear region of the upper surface of the nozzle plate 17. When each shutter plate 132 moves to a position where the upper side of the nozzle 17a is blocked, the nozzle 17a is in a closed state.

The front shutter plate driving unit 133a moves the front shutter plates 132a1 to 132an in the front-rear direction independently of each other. The rear shutter plate driving unit 133b moves the rear shutter plates 132b1 to 132bn in the front-rear direction independently of each other. The k-th front shutter plate 132ak (k is any one of 1 to n) from the right and the k-th rear shutter plate 132bk from the right correspond to the row of the k-th nozzle 17a from the right. The left-right position of each shutter plate 133 coincides with the left-right position of the corresponding row of nozzles 17a.

In the present embodiment, each nozzle 17a (each nozzle 17a within a predetermined range on the front end side) corresponding to Ya rows (for example, 4 rows) from the front is a specific nozzle that is opened and closed by the corresponding front shutter plate 132a. The nozzles 17a (each nozzle 17a within the predetermined range on the rear end side) corresponding to the Yb row (for example, four rows) are the specific nozzles that are opened and closed by the rear shutter plate 132b.

The front shutter plate driving unit 133a is disposed in the vicinity of the front edge of the nozzle plate 17 and moves the front shutter plates 132a in the front-rear direction by pushing them back or pulling them forward. As a result, the state of the front shutter plate 132ak is a state in which none of the nozzles 17a is blocked, a state in which the nozzle 17a from the front side to the first row from the right side is blocked,. Thus, switching is possible between a state in which the nozzles 17a from the front side to the Ya row are closed.

The rear shutter plate drive unit 133b is disposed in the vicinity of the rear edge of the nozzle plate 17, and pushes each rear shutter plate 132b forward or retracts backward to move in the front-rear direction. As a result, the state of the rear shutter plate 132bk is a state where none of the nozzles 17a is blocked, a state where the nozzle 17a from the rear and the first row from the rear is blocked,..., And k from the right It is possible to switch between the states where the nozzles 17a from the rear side to the Yb-th row are closed.

Each shutter plate 132 is movable between an open position for opening the opening of the specific nozzle and a closed position for closing the opening so as to slide on the upper surface of the nozzle plate 17, and can be used for opening and closing the specific nozzle. In the present embodiment, each shutter plate 132 is provided so as to slide on the upper surface of the nozzle plate 17, but instead, each shutter plate 132 may be provided so as to slide on the lower surface of the nozzle plate 17.

In this embodiment, for each row of nozzles 17a arranged in the front-rear direction, one shutter plate 132 that is independently driven is provided on both the front side and the rear side. Thereby, the opening and closing of the nozzles 17a can be controlled in units of the row, and the thickness of the FTS 3 to be manufactured can be changed in the left-right direction.

3. Third Embodiment Next, a third embodiment of the present invention will be described. The third embodiment is basically the same as the first embodiment except for the point related to the first unit. In the following description, emphasis is placed on the description of contents different from the first embodiment, and description of contents common to the first embodiment may be omitted.

FIG. 16 is a schematic configuration diagram from an upper viewpoint of the first unit Z1b according to the third embodiment. 17A is a cross-sectional view taken along the line BB ′ of the first unit Z1b shown in FIG. 16, and FIG. 17B is a cross-sectional view taken along the line CC ′ of the first unit Z1b shown in FIG. FIG.

The first unit Z1 includes a nozzle plate 17, shutter plates 232 (front shutter plates 232a1 to 232a4 and rear shutter plates 232b1 to 232b4) disposed on the nozzle plate 17, and shutters for driving the shutters 232. A plate driving unit 233 (the right shutter plate driving unit 233a and the left shutter plate driving unit 233b) is provided. The configuration of the nozzle plate 17 is basically the same as the nozzle plate 17 of the first embodiment except that a restriction hole 17b described later is provided.

Each shutter plate 232 is a metal plate having a thickness in the range of 3 mm to 20 mm, and is movably disposed in the horizontal direction (more specifically, in the left-right direction) along the upper surface of the nozzle plate 17. Each shutter plate 232 is movable so as to open and close a predetermined nozzle 17 a (specific nozzle) while discharging the molten filament 2 from the extrusion molding machine 10. Each shutter plate 232 has a plate shape extending in the left-right direction, and the width in the front-rear direction is substantially equal to the pitch in the front-rear direction of each nozzle 17a.

The front shutter plates 232a1 to 232a4 are movable in the left-right direction in the front region of the upper surface of the nozzle plate 17. On the other hand, the rear shutter plates 232b1 to 232b4 are movable in the left-right direction in the rear region of the upper surface of the nozzle plate 17. When each shutter plate 232 moves to a position that closes the upper side of the nozzle 17a, the nozzle 17a is closed.

The kth front shutter plate 232ak (k is any one of 1 to 4) from the front corresponds to the row of the kth nozzles 17a from the front. The k-th rear shutter plate 232bk from the rear corresponds to the row of the k-th nozzle 17a from the rear. The front-rear direction position of each shutter plate 233 coincides with the front-rear direction position of the corresponding row of nozzles 17a.

In this embodiment, the nozzles 17a for the four rows from the front (the nozzles 17a within the predetermined range on the front end side) are specific nozzles that are opened and closed by the corresponding front shutter plates 232a1 to 232a4. The four rows of nozzles 17a (the nozzles 17a within the predetermined range on the rear end side) are specific nozzles that are opened and closed by the rear shutter plates 232b1 to 232b4.

As shown in FIG. 17A, restriction holes 17 b having a predetermined width in the left-right direction are provided in the vicinity of both left and right ends of the nozzle plate 17, and extend downward in the vicinity of both ends of each shutter plate 232. A protrusion 252 is provided. Each protrusion 252 is fitted in the restriction hole 17b, and the movable range in the left-right direction is restricted by the left-right width of the restriction hole 17b. The right shutter plate driving unit 233 a is disposed in the vicinity of the right edge of the nozzle plate 17 and has a driving mechanism connected to the right protrusion 252 of each shutter plate 232. The left shutter plate driving unit 233 b is disposed in the vicinity of the left edge of the nozzle plate 17 and has a driving mechanism connected to the left end protrusion 252 of each shutter plate 232. By these drive mechanisms, the shutter plates 232 can be moved in the left-right direction independently of each other within the range of the restriction (that is, between an open position and a closed position described later).

Each shutter plate 232 is formed to have an opening 251 corresponding to each specific nozzle on a wall portion that is movable in the left-right direction along the upper surface of the nozzle plate 17 (the surface including the opening of each nozzle 17a). ing. For example, the front shutter plate 232a1 is formed to have openings 251 corresponding to the nozzles 17a in the first row from the front.

The one shutter plate 232 is provided with a plurality of openings 251 arranged in a line in the left-right direction, and the number and pitch in the left-right direction are equivalent to the number and pitch in the left-right direction of the nozzles 17a. The xth opening 251 from the left corresponds to the xth nozzle 17a from the left. The shape of the opening 251 from the upper viewpoint is the same circle as the opening of the nozzle 17a, and the diameter of the opening 251 is set equal to or slightly larger than the diameter of the opening. The pitch in the left-right direction of the nozzles 17a is larger than the diameter of the nozzles 17a, and the pitch in the left-right direction of the openings 251 is larger than the diameter of the openings 251.

Each shutter plate 232 is movable between an open position for opening the opening of the specific nozzle and a closed position for closing the opening so as to slide on the upper surface of the nozzle plate 17, and can be used for opening and closing the specific nozzle. The open position in the present embodiment is a position where the opening 251 overlaps with the corresponding specific nozzle (a position where the molten filament 2 can be discharged through the opening 251). In the example shown in FIG. 16, the front and rear shutter plates 232a3 and 232a4 in the third and fourth rows from the front, and the rear shutter plates 232b3 and 232b4 in the third and fourth rows from the rear are positioned in the open position. It is in a state.

In the present embodiment, the closed position is a position where the opening 251 overlaps between the corresponding specific nozzle and the adjacent specific nozzle (a position where the wall adjacent to the opening 251 closes the specific nozzle). In the example shown in FIG. 16, the front shutter plates 232a1, 232a2 in the first row and the second row from the front, and the rear shutter plates 232b1, 232b2 in the first row and the second row from the rear are positioned at the closed position. It is in a state.

The amount of movement required to move each shutter plate 232 between the open position and the closed position is about the diameter of the opening of the nozzle 17a. Therefore, in this embodiment, the moving distance of the shutter plate 232 required for opening and closing the nozzle 17a is very short, and opening and closing can be performed quickly and more accurate opening and closing control is possible. In addition, even when a specific nozzle near the center located far from the front and rear direction end is opened and closed, the moving distance of the shutter plate 232 required to open and close the nozzle 17a can be shortened in the same manner, and the same effect can be obtained. It is possible to obtain. In this embodiment, each shutter plate 232 is provided so as to slide on the upper surface of the nozzle plate 17, but instead, each shutter plate 232 may be provided so as to slide on the lower surface of the nozzle plate 17.

4). Summary The embodiments of the present invention have been described above. However, the configuration of the present invention is not limited to the above embodiments, and various modifications can be made without departing from the spirit of the invention. That is, the above-described embodiment is an example in all respects, and should be considered as not restrictive. The technical scope of the present invention is shown not by the above description of the embodiment but by the scope of the claims, and is understood to include all modifications within the meaning and scope equivalent to the scope of the claims. Should.

The present invention can be used for manufacturing an FTS used for a mattress, a pillow, a cushion, or the like.

1 ... Filament three-dimensional joined body manufacturing apparatus (FTS manufacturing apparatus)
2 ... Molten filament 3 ... Filament three-dimensional combination (FTS)
DESCRIPTION OF SYMBOLS 10 ... Extruder 11 ... Pressure part 11a ... Cylinder 11b ... Filament discharge part 12 ... Die 12a ... Die guide flow path 13 ... Hopper 14 ... Screw 15・ ・ ・ Screw motor 16 ・ ・ ・ Screw heater 17 ・ ・ ・ Nozzle plate 17a ・ ・ ・ Nozzle 18 (18a to 18f) ・ ・ ・ Die heater 20 ・ ・ ・ Three-dimensional combined body forming device 21 (21a, 21b) ··· Receiving plate 22 ··· Cooling device 22a ··· Cooling water 23 ··· Water tank 24 (24a and 24b) ··· Conveyor 25a to 25h ··· Conveyance roller 30 · · · Thickness direction position controller 32a, 32b) ... shutter plate (first embodiment)
33 (33a, 33b) ... Shutter plate driving section (first embodiment)
132 (132a, 132b) ... Shutter plate (second embodiment)
133 (133a, 133b) ... Shutter plate driving unit (second embodiment)
232 (232a, 232b) ... Shutter plate (third embodiment)
233 (233a, 233b) ... Shutter plate driving unit (third embodiment)
34 ... Shutter plate control unit 35 ... Reception plate control unit 36 ... Conveyor control unit

Claims (10)

A molten filament supply device for discharging a molten filament from each of a plurality of nozzles;
A three-dimensional combined body forming apparatus for fusing and bonding the discharged molten filament group to form a filament three-dimensional combined body,
The molten filament supply device comprises:
An apparatus for manufacturing a filament three-dimensional combination, comprising: an opening / closing part that opens and closes a specific nozzle that is at least one of the plurality of nozzles. The opening / closing part is
A shutter member that is movable between an open position for opening the opening and a closed position for closing the opening so as to slide the surface including the opening of the specific nozzle;
The filament three-dimensional joined body manufacturing apparatus according to claim 1, wherein the opening and closing is performed by moving the shutter member. A plurality of the specific nozzles arranged in a predetermined direction are provided,
The shutter member is
It has an opening corresponding to each of the specific nozzles, is formed movably in the predetermined direction,
The open position is
The opening is a position overlapping the corresponding specific nozzle;
The closed position is
3. The filament three-dimensional assembly manufacturing apparatus according to claim 2, wherein the opening is a position overlapping between the corresponding specific nozzle and the adjacent specific nozzle. The molten filament supply device comprises:
The plurality of nozzles are arranged in a horizontal direction including a first direction, and supply the molten filament group vertically downward;
4. The filament three-dimensional assembly manufacturing apparatus according to claim 1, wherein among the plurality of nozzles, the specific nozzle is within a predetermined range on the first direction end side. 5. . The molten filament supply device comprises:
The plurality of nozzles are arranged in a horizontal direction including the first direction which is the predetermined direction, and supply the molten filament group vertically downward,
4. The filament three-dimensional assembly manufacturing apparatus according to claim 3, wherein among the plurality of nozzles, the specific nozzles are arranged in a direction orthogonal to the first direction on the first direction end side. The three-dimensional combined body forming apparatus includes:
Having a receiving plate for bringing the end of the first direction of the molten filament group into contact with the surface inclined with respect to the vertical direction and guiding it to the center side of the molten filament group;
The filament three-dimensional joined body manufacturing apparatus according to claim 4 or 5, wherein the position of the backing plate is controlled in the first direction. The three-dimensional combined body forming apparatus includes:
A first backing plate for bringing one end of the molten filament group in the first direction into contact with a surface inclined with respect to the vertical direction and leading to the center side of the molten filament group; and a first direction of the molten filament group A second receiving plate having a second receiving plate that is brought into contact with a surface inclined with respect to the vertical direction and led to the center side of the molten filament group,
The filament three-dimensional assembly manufacturing apparatus according to claim 4 or 5, wherein each of the pair of receiving plates is position-controlled in a first direction. The three-dimensional combined body forming apparatus includes:
A conveyor that is in contact with the first direction end of the molten filament group and is driven to convey the end downstream;
The apparatus for manufacturing a filament three-dimensional combination according to any one of claims 4 to 7, wherein the position of the conveyor is controlled in the first direction. The three-dimensional combined body forming apparatus includes:
A first conveyor that is in contact with one end of the molten filament group in the first direction and is driven to convey the end portion downstream; and a second conveyor in the first direction of the molten filament group; A pair of conveyors having a second conveyor driven to convey the end portion downstream,
The filament three-dimensional assembly manufacturing apparatus according to any one of claims 4 to 7, wherein the position of each of the pair of conveyors is controlled in the first direction. A method of discharging a molten filament vertically downward from a plurality of nozzles arranged in a horizontal direction including a first direction, and manufacturing a filament three-dimensional combination using the discharged molten filament group,
A control step of controlling the position in the first direction of the end portion by opening and closing the nozzle corresponding to the end portion in the first direction of the molten filament group;
By guiding the first direction end of the molten filament group to the center side of the molten filament group, the first direction position of the end filament is regulated to a regulation position set to be changeable, and the end is dense. A densification step to produce a group of melted filaments;
Forming a filament three-dimensional combination by fusing and bonding the densified molten filament group,
The control step includes
A filament three-dimensional joined body manufacturing method characterized by controlling a first direction position of a first direction end portion of the molten filament group according to the regulation position.

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