JPS61207655A - Hard cotton molded article and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] (Industrial application field) The present invention relates to a hard cotton molded product and a method for manufacturing the same.

(Prior art) Non-woven fabric made of a laminate of synthetic fibers, V-shaped hardness,
This is a method for forming an uneven pattern on fibers such as knitted and woven fabrics made of synthetic fiber yarn.

An embossing method is generally known in which the above-mentioned fiber sheet is passed through a nip between a metal heating roller having an uneven pattern and a soft lobe such as cotton wool.

It was. Particularly hard convex portions can be formed by impregnating the convex portions with synthetic resin or by impregnating the convex portions with synthetic resin or wood.

A method is known in which a solid material such as a metal is fixed to the above-mentioned fibers y, ) by adhesive or the like.

Although the embossing method is extremely efficient, the purpose of the embossing method is to uniformly heat the entire surface of the fiber sheet for the purpose of visual beauty. / -) is heat-set into an uneven pattern on the surface of a metal roller, so the hardness of the base part and the four convex pattern parts is the same, and the hardness is almost the same as before processing. When processed into shoe insoles, etc., the 6-fold pattern was flexible, so it was not possible to obtain the same stimulation as acupressure. and.

In order to harden the convex parts, the surface temperature of the metal roller is increased to fuse the fibers in the fiber sheet, and the next time, the base part is also fused in the same way, resulting in a texture as a fiber sheet. This results in a loss of breathability and cushioning properties.

Also, if a hard solid object is attached, it is difficult to install it.

There is a problem that foreign matter attached to the fiber sheet impairs its texture and falls off during use.

The present inventor first pressure-welded a tool horn of an ultrasonic welder to a part of hard cotton, applied ultrasonic vibration to the tool horn to form an uneven shape, and fused the fibers in this formed part. This part hardens and fc [9] I proposed an invention related to molded products. This is because all of the molded parts harden and become plastic-like, making them too hard and painful when used in parts that come into direct contact with the body, such as health futons and shoe insoles. It was true.

(Problems to be Solved by the Invention) The present invention aims to provide (1) a molded product with appropriate cushioning properties and acupressure effect when processed into, for example, a health futon or an insole for shoes, and a method for producing the same; Purpose - (Measures for Solving Problems) The present invention is characterized in that a part of a rubber hardness made of synthetic fibers with a hardness of 5 degrees or more and less than 90 degrees is formed into a convex shape, and the convex shape The part other than the top part is harder than the above-mentioned hardness, and it may be hard.
It has been melted and hardened.

A molded product whose top part has a rubber hardness of 5 degrees or more and less than 90 degrees, and a rubber hardness of 5 degrees or more and less than 90 degrees made of synthetic fiber. The upper mold is formed into a shape with the tip part missing from the shape that fits with the lower mold, and is pressed against the tool horn of the ultrasonic helder, and the tool horn is subjected to ultrasonic vibration. It is a method of manufacturing something.

Here, the hardness can be obtained by laminating card webs obtained by passing synthetic fiber short fibers through a card and then needle punching them, or by mixing binder fibers into the short fibers in advance and passing them through a card, laminating card webs to a predetermined thickness. It can be obtained by heating the web while compressing it to melt the binder fibers and maintain the shape of the web. If the hardness is less than 5 degrees of rubber hardness.

Although it is soft and flexible, it does not retain its shape well and has poor handling and functionality. When the rubber hardness is 90 degrees or more.

It is undesirable to be too hard and have no elasticity or cushioning properties. A rubber hardness of 20 to 60 degrees is most preferred. As shown in the embodiment of FIG. 1, the hard cotton is formed into a convex shape, and the portion 2 excluding the top of the convex shape is hardened and fused to be harder than the above-mentioned hard cotton. The preferred hardness is a rubber hardness of 90-100 degrees.

This portion 2 is of course made of binder fiber.

Synthetic short fibers are fused and become plastic-like, with a surface rubber hardness of 90 to 100 degrees. The top part 3 of the convex shape is not hardened and fused, and the hardness of the hard cotton remains as it is, and the rubber hardness is 5 degrees or more and 90 degrees.
less than 1 degree. In addition.

In the present invention, rubber hardness is measured using an F-type rubber hardness meter manufactured by Kobunshi Keiki Co., Ltd.

The hard cotton molded product of the present invention can be obtained as follows. (See Figures 2 and 3 for description as an example.

) A sheet of hard cotton l is sandwiched between a lower die 4 and a tool horn (upper die) 5. The lower die 4 has a downwardly convex portion, and the tool horn (upper die) fits into the lower die 4, but its tip has a missing shape and has a good shape. When ultrasonic vibrations are applied to the tool horn 5, the synthetic fibers in the nine sandwiched parts of the tL 21 generate heat due to internal friction caused by the ultrasonic vibrations, and are fused and compressed in an extremely short period of several seconds. In particular, the apparent volume decreases, the hardness increases, and the remaining area remains in its original state. The preferred frequency of ultrasonic vibration is 10 to 50 KHz. *The preferred amplitude is 18 μ or more. If the frequency and amplitude are out of the above range, 1) It will take a long time to generate heat, and 2) it will not generate heat. do. [When hard cotton is formed by mixing synthetic fibers with a relatively high melting point and synthetic fibers with a relatively low melting point, the ultrasonic vibration is stopped at the stage when the synthetic fibers with a relatively low melting point have melted. .

The appearance and texture of the hardened convex portion A can be made the same as that of the base portion by leaving the high melting point synthetic fiber in the form of fibers.

Also, when pressing the tool horn 5.

By restricting its entry to a certain limit by the stopper 8, the thickness of the convex portion A to be cured can be easily controlled. Part 2, excluding the top of the convex shape, is hardened to be harder than the hard cotton part, so it can be used for health futons, pillows, chair backs, slippers, shoe insoles, etc. Appropriate hardness is obtained to provide an acupressure-like effect, and if the above-mentioned stiffness is less than 90 degrees, the shape is likely to be lost due to weight.

The present invention eliminates the tip shape of the tool horn in the fitting shape with the upper mold and lower mold, and thickens only the tip when it meets the lower mold to prevent hardening. A hard plastic convex convex shape is molded into a part of the body, and only the top of the convex tip is soft to provide appropriate cushioning properties and hardness.

(Examples) The present invention will be explained below with reference to Examples, but the present invention is not limited to these Examples.

High melting point cut 8 made of drawn polyester fibers (melting point 263°C, thickness IO Denny/I/, fiber length 64m!1
) and 20% of a low melting point binder fiber made of undrawn polyester fiber (melting point 130°C, thickness 4 denier 1v, fiber length 51fi) was laminated to form a 160%
℃ to obtain a hardness of 9l with a rubber hardness of 37 degrees, thickness of 20ff, and basis weight of 800f/jl/, and this hardness of 9l as shown in Fig. Fix it on mold 4.

The tip 5a is formed into a hemispherical shape with a diameter of 30ff, and the tip 10fl is cut horizontally so that the tool horn 5 is lowered (see Fig. 3), and the electric signal generated by the ultrasonic oscillator 6 is transmitted to the vibrator 7. Mechanical vibration (frequency 15 KHz,
An amplitude of 25μ) is transmitted to the tool horn 5, and the welding time is 3 seconds to produce a hard cotton molded product in which only the top of the convex shape shown in FIG. 1 is made of soft hardwood. The rubber hardness of the obtained convex portion 2 excluding the top part is 98 degrees and the thickness is 1! It is made of Ig, and its surface is covered with fibers and has fluff.

It has the same texture as the ground part. The rubber hardness of the top part 3 of the convex and convex shape was 60 degrees, and the maximum thickness was 7fl. It was formed to a length of 200 mm, and convex portions were formed on the entire surface at intervals of 8 cm using the method described above. When used as a futon, the entire body had moderate cushioning properties, and the convex portions A were The following can give the effect of acupressure without deformation.

(Effects of the Invention) In the hard molded product of the present invention, the base portion and the convex top portion maintain the same properties, and only the portion other than the uneven convex top portion is compressed. It is made into a resin and hardened by fusing the fibers, so by appropriately setting the size of the convex part A, it can be used to create pillows, health futons, pillows, slippers, shoe insoles, chair backrests, etc. It can be used as a shiatsu effect using your body weight, and it also has the original cushioning properties of hard cotton, 1 elasticity, 1
It does not lose its breathability and texture, and since the convex part after hardening is integrated with the hard ground and the top of the convex shape, it will not peel off, fall off, or become damaged. . 11 Since the method for manufacturing the hard molded product of the present invention uses an ultrasonic welder, the hard molded product of the present invention can be manufactured in an extremely short time of several seconds, and the time for applying ultrasonic vibration is The hardness of the patterned part can be changed by adjusting the angle, and by cutting off the tip of the tool horn horizontally, only the top of the convex part leaves a soft ridged part, resulting in molding with a curved part. 0 friends who can get things

[Brief explanation of drawings]

Figure 1 is a sectional view of an example of a hard cotton molded product, Figure 2 is an explanatory diagram of an example of an apparatus for manufacturing a hard cotton molded product, and Figure 3 is a cross-sectional view of an example of a hard cotton molded product.
FIG. 3 is an explanatory diagram of the operation of the lower die portion in the figure. A: Convex portion l: Hardness 9 2: Part excluding the top of the convex 3: Top of the convex 4: Bottom mold 5: Tool horn 5a: Tip of the tool horn 6: Ultrasonic oscillator of ultrasonic welder 7: Vibrator

Claims (2)

[Claims] (1) A part of hard cotton made of synthetic fibers with a rubber hardness of 5 degrees or more and less than 90 degrees is formed into a convex shape, and the part other than the top of the convex shape is harder than the hard cotton and is melted. A hard cotton molded product that is cured and has a rubber hardness of 5 degrees or more and less than 90 degrees at the top. (2) A part of a sheet-like hard cotton made of synthetic fibers with a rubber hardness of 5 degrees or more and less than 90 degrees is supported by a lower mold, and the upper mold is placed on the upper surface of the sheet, and the tip is removed from the shape that fits with the lower mold. 1. A method for producing a hard cotton molded article, which comprises press-welding a tool horn of an ultrasonic welder formed into a shape, and applying ultrasonic vibration to the tool horn.