U.S. patent application number 14/403670 was filed with the patent office on 2015-06-04 for nonwoven fabric manufacturing apparatus and nonwoven fabric manufacturing method.
The applicant listed for this patent is NIPPON NOZZLE CO., LTD.. Invention is credited to Oki Kitamura, Yasuhiko Otani, Mitsuaki Saeki, Toshiaki Washimoto.
Application Number | 20150152571 14/403670 |
Document ID | / |
Family ID | 49673483 |
Filed Date | 2015-06-04 |
United States Patent
Application |
20150152571 |
Kind Code |
A1 |
Otani; Yasuhiko ; et
al. |
June 4, 2015 |
NONWOVEN FABRIC MANUFACTURING APPARATUS AND NONWOVEN FABRIC
MANUFACTURING METHOD
Abstract
Provided is a nonwoven fabric manufacturing apparatus and a
nonwoven fabric manufacturing method capable of equally coping with
minute dimensional differences while reducing cost in response to
various dimensional requirements. The nonwoven fabric manufacturing
apparatus includes a die 2 having a nozzle row 20, a resin supply
means 3 supplying the thermoplastic resin to the die 2, a hot air
supply means 8 supplying hot air to a thermoplastic resin extruded
from the nozzle row 20 of the die 2 to draw the thermoplastic resin
into fibers, and a collector 5 having a conveyor belt 11, the
collector 5 collecting the thermoplastic resin that has been drawn
into fibers to form a nonwoven fabric web 12 by the self-fusion
property.
Inventors: |
Otani; Yasuhiko; (Kobe-shi,
JP) ; Saeki; Mitsuaki; (Akashi-shi, JP) ;
Washimoto; Toshiaki; (Nishinomiya-shi, JP) ;
Kitamura; Oki; (Higashiosaka-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIPPON NOZZLE CO., LTD. |
Kobe-shi |
|
JP |
|
|
Family ID: |
49673483 |
Appl. No.: |
14/403670 |
Filed: |
June 3, 2013 |
PCT Filed: |
June 3, 2013 |
PCT NO: |
PCT/JP2013/065409 |
371 Date: |
November 25, 2014 |
Current U.S.
Class: |
264/555 ;
425/72.2 |
Current CPC
Class: |
D04H 3/16 20130101; D04H
1/72 20130101; D01D 5/0985 20130101; D01D 4/025 20130101; D04H 3/03
20130101; D04H 1/56 20130101 |
International
Class: |
D01D 4/02 20060101
D01D004/02; D01D 5/098 20060101 D01D005/098 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 1, 2012 |
JP |
2012-126572 |
Sep 21, 2012 |
JP |
2012-208059 |
Claims
1: A nonwoven fabric manufacturing apparatus comprising: a die
having a nozzle row, the nozzle row extruding a thermoplastic
resin; a resin supply means supplying the thermoplastic resin to
the die; a hot air supply means supplying hot air to the
thermoplastic resin extruded from the nozzle row of the die to draw
the thermoplastic resin into fibers; and a collector having a
conveyor belt, the collector collecting the thermoplastic resin
that has been drawn into fibers to form a web by the self-fusion
property; wherein the die is disposed in such a manner that the
angle of the die can be changed in a direction inclined relative to
a width direction of the web that is perpendicular to a moving
direction of the conveyor belt so that a width dimension of the web
to be formed can be adjusted to a dimension corresponding to the
angle of the die.
2: The nonwoven fabric manufacturing apparatus according to claim
1, wherein a resin inflow port of the die is turnably attached to a
resin supply port of the resin supply means so that the angle of
the die can be changed by adjusting a turning angle of the
attachment.
3: The nonwoven fabric manufacturing apparatus according to claim
2, wherein an attachment structure between the resin inflow port of
the die and the resin supply port of the resin supply means is a
butt connection structure between flanges and the flanges can be
fixed to each other with changing an angle therebetween.
4: The nonwoven fabric manufacturing apparatus according to claim
3, wherein the flanges can be fixed to each other with changing the
angle therebetween using a quick coupling.
5: The nonwoven fabric manufacturing apparatus according to claim
1, wherein the die is provided with slits as the hot air supply
means through which hot air is blown out from both sides across the
nozzle row.
6: The nonwoven fabric manufacturing apparatus according to claim
1, wherein the collector includes a mesh-like conveyor belt and a
suction box that sucks air on an upper surface of the belt from a
rear surface of the belt, and at least a suction unit of the
suction box that faces the die across the conveyor belt is disposed
in such a manner that the angle thereof can be changed to a
direction inclined relative to the web width direction that is
perpendicular to the conveyor belt moving direction.
7: The nonwoven fabric manufacturing apparatus according to claim
6, further comprising an interlocking mechanism that changes at
least the angle of the suction unit of the suction box in
interlocking with angle change of the die.
8: A nonwoven fabric manufacturing apparatus in which a resin
inflow port of a die having a nozzle row that extrudes a
thermoplastic resin is turnably attached to a resin supply port of
a resin supply means, wherein an expansion portion having an outer
peripheral surface whose diameter expands toward a tip in a fan
shape is provided in one of the resin inflow port and the resin
supply port, a recessed portion is provided in the other one of the
resin inflow port and the resin supply port, the recessed portion
having an inner peripheral surface whose diameter decreases toward
a tip and receiving the expansion portion inside thereof to allow
the outer peripheral surface to abut on the inner peripheral
surface to lock the expansion portion relatively rotatably in a
circumferential direction as well as inseparably in an axial
direction, and the resin inflow port of the die is turnably
attached to the resin supply port of the resin supply means by a
support structure that includes the expansion portion and the
recessed portion.
9: The nonwoven fabric manufacturing apparatus according to claim
8, wherein the expansion portion is formed on an outer periphery of
a tip of a joint tube that constitutes the resin inflow port or an
outer periphery of a tip of a resin supply tube that constitutes
the resin supply port.
10: The nonwoven fabric manufacturing apparatus according to claim
8, wherein the recessed portion includes a flange that is formed on
an outer periphery of a tip of a resin supply tube that constitutes
the resin supply port or an outer periphery of a tip of a joint
tube that constitutes the resin inflow port and a holding cylinder
that is disposed in a protruding manner on a tip surface of the
flange and has the inner peripheral surface.
11: The nonwoven fabric manufacturing apparatus according to claim
8, wherein the outer peripheral surface of the expansion portion is
formed in a conical surface and the inner peripheral surface of the
recessed portion is formed in a conical hole surface that faces the
outer peripheral surface in parallel thereto.
12: A nonwoven fabric manufacturing apparatus in which a resin
inflow port of a die having a nozzle row that extrudes a
thermoplastic resin is turnably attached to a resin supply port of
a resin supply means, wherein one of the resin inflow port and the
resin supply port includes a cylindrical portion and an expansion
portion having an outer peripheral surface whose diameter expands
on a tip of the cylindrical portion, a holding body is provided in
the other one of the resin inflow port and the resin supply port,
the holding body having a recessed portion receiving the expansion
portion inside thereof to lock the expansion portion relatively
rotatably in a circumferential direction as well as inseparably in
an axial direction, a cylindrical support portion is provided in a
region on a tip of the holding body, the cylindrical support
portion having an inner peripheral surface that is continuous with
an inner surface of the recessed portion and relatively rotatably
supports an outer peripheral surface of the cylindrical portion,
and the resin inflow port of the die is turnably supported with
respect to the resin supply port of the resin supply means by a
support structure that includes the expansion portion and the
holding body.
13: The nonwoven fabric manufacturing apparatus according to claim
12, wherein a bearing member is interposed between the outer
peripheral surface of the cylindrical portion and the inner
peripheral surface of the cylindrical support portion.
14: The nonwoven fabric manufacturing apparatus according to claim
12, wherein a bearing member is interposed between an outer surface
of the expansion portion, the outer surface facing a base end side
of the expansion portion, and an inner surface of the recessed
portion of the holding body, the inner surface facing a base end
side of the recessed portion and being opposed to the outer surface
of the expansion portion.
15: The nonwoven fabric manufacturing apparatus according to claim
12, wherein a seal member surrounding a resin flow path is disposed
between an outer surface of the expansion portion, the outer
surface facing a tip side of the expansion portion, and an inner
surface of the recessed portion of the holding body, the inner
surface facing a tip side of the recessed portion and being opposed
to the outer surface of the expansion portion.
16: The nonwoven fabric manufacturing apparatus according to claim
12, wherein the cylindrical portion is composed of a joint tube
that constitutes the resin inflow port or a resin supply tube that
constitutes the resin supply port, and the expansion portion is
formed on an outer periphery of a tip of the joint tube or an outer
periphery of a tip of the resin supply tube.
17: The nonwoven fabric manufacturing apparatus according to claim
12, wherein the holding body includes a flange that is formed on an
outer periphery of a tip of a resin supply tube that constitutes
the resin supply port or an outer periphery of a tip of a joint
tube that constitutes the resin inflow port and a holding cylinder
that is disposed in a protruding manner on a tip surface of the
flange and has the recessed portion and the cylindrical support
portion continuous with the recessed portion.
18: The nonwoven fabric manufacturing apparatus according to claim
12, wherein the outer peripheral surface of the expansion portion
is parallel to the outer peripheral surface of the cylindrical
portion, and the holding body includes a recessed portion having an
inner peripheral surface parallel to the outer peripheral surface
of the expansion portion and a cylindrical support portion having
an inner peripheral surface whose diameter decreases in a stepwise
manner continuously with the recessed portion, the inner peripheral
surface being parallel to the outer peripheral surface of the
cylindrical portion.
19: A nonwoven fabric manufacturing method comprising: preparing a
nonwoven fabric manufacturing apparatus, the apparatus includes a
die having a nozzle row, the nozzle row extruding a thermoplastic
resin, a resin supply means supplying the thermoplastic resin to
the die, a hot air supply means supplying hot air to a
thermoplastic resin extruded from the nozzle row of the die to draw
the thermoplastic resin into fibers, and a collector having a
conveyor belt, the collector collecting the thermoplastic resin
that has been drawn into fibers to form a web by the self-fusion
property; disposing the die in such a manner that the angle of the
die can be changed in a direction inclined relative to a width
direction of the web that is perpendicular to a moving direction of
the conveyor belt; and adjusting a width dimension of the web to be
formed to a dimension corresponding to the angle of the die by
changing the angle of the die.
Description
TECHNICAL FIELD
[0001] The present invention relates to a nonwoven fabric
manufacturing apparatus and a nonwoven fabric manufacturing method
which draw a thermoplastic resin extruded from a die into fibers
with hot air to manufacture a nonwoven fabric, and particularly, to
a nonwoven fabric manufacturing apparatus and a nonwoven fabric
manufacturing method suitable for a melt-blown nonwoven fabric
manufacturing apparatus which draws a thermoplastic resin extruded
from a die having a nozzle row into fibers to manufacture a
nonwoven fabric.
BACKGROUND ART
[0002] Recently, nonwoven fabrics have been widely used in devices
for automobile or the like. Further, the type of automobile has
been diversified according to requests of customers, and there have
been increasing cases in which the design of devices even for the
same use in which nonwoven fabrics are used changes depending on
the type of automobile. Thus, nonwoven fabrics having various
dimensions tend to be requested by, for example, automobile
manufactures with a small amount for each dimension.
[0003] A nonwoven fabric manufacturing apparatus employs a melt
spinning method which jets a thermoplastic resin extruded through
fine holes of a nozzle head of a die with hot air to thereby draw
the thermoplastic resin into fibers, and collects the fibers on a
conveyor to form a web by the self-fusion property thereof (refer
to Patent Documents 1 to 3, for example). The die is disposed along
a direction perpendicular to a moving direction of the conveyor,
that is, a width direction of the web to be formed. The nozzle row
of the die in which the many fine holes are arrayed also extends in
the direction perpendicular to the moving direction of the
conveyor. The width dimension of a nonwoven fabric obtained as the
web in this manner is determined to be a fixed width depending on
the length of the nozzle row of the spin head.
[0004] Thus, the following operation has been conventionally
performed. Specifically, a die corresponding to a specific
dimension is prepared for replacement, or a nonwoven fabric having
a width corresponding to a device for an automobile of a specific
type having high yield is manufactured and the manufactured
nonwoven fabric is, for example, further cut so as to correspond to
a specific dimension and supplied in response to a request for
another product having the specific dimension. However, when
replacing dies for each dimension, the replacement operation takes
time and cost for preparing various types of dies increases.
Further, the number of dies to be prepared is limited. Thus, it is
not possible to cope with minute dimensional differences. Further,
adjusting the dimension by cutting increases the number of steps
and causes deterioration of the cutting yield, which
disadvantageously causes an increase in manufacturing cost and
variation in dimension.
[0005] More specifically, the melt-blown nonwoven fabric
manufacturing method as described in Patent Documents 1 to 3 is
widely used mainly for manufacturing a material for a filter as a
technique of manufacturing a nonwoven fabric made of fine fibers of
1 .mu.m or less to 10 and several .mu.m. The technique draws molten
resin flows ejected from a nozzle row in which fine holes having a
diameter of, for example, 0.15 mm are arranged in a linear manner
at a fine pitch with a high-speed air flow and collects the drawn
molten resin flows on a moving conveyor to thereby obtain a
nonwoven fabric having a width equal to the length of the nozzle
row. FIG. 17 is a schematic view of a melt-blown method wherein
molten resin flows 10 extruded from a nozzle row 20 of a die 2 are
collected on a conveyor 11 which is running in a direction
indicated by an arrow to thereby form a nonwoven fabric 12.
[0006] The most important device for carrying out this technique is
a nozzle. In particular, in order to obtain fine fibers, a nozzle
that has a nozzle row having holes with a diameter of 0.15 mm or
less is required and machining for the nozzle takes several months.
Further, when the length of the nozzle is 1 m or more, the cost
thereof also becomes extremely high. Further, preparing both an
appropriate die and an appropriate nozzle requires a higher cost.
For example, in order to obtain a nonwoven fabric having a width of
0.9 m when manufacturing a nonwoven fabric having a width of 1 m,
the formed nonwoven fabric having a width of 1 m is cut by a 0.1 m
width and the cut piece is discarded. As a result, a waste material
is disadvantageously generated. If a die and a nozzle capable of
manufacturing a nonwoven fabric having a width of 0.9 m are
prepared in order to avoid the above problem, the high cost as
described above is required. Further, down-time of the machine is
made longer because of such replacement of dies, which also leads
to a reduction in the productivity.
[0007] Patent Document 1: JP-A No. H02-289107
[0008] Patent Document 2: JP-A No. H09-49111
[0009] Patent Document 3: JP-A No. 2002-38326
SUMMARY OF INVENTION
Technical Problem
[0010] In view of the above circumstances, an object of the present
invention is to provide a nonwoven fabric manufacturing apparatus
and a nonwoven fabric manufacturing method capable of equally
coping with minute dimensional differences while reducing cost in
response to various dimensional requirements, reducing equipment
investment, and obtaining nonwoven fabrics having different widths
without reducing the productivity.
Solution to Problem
[0011] In order to solve the above problems, the present invention
provides a nonwoven fabric manufacturing apparatus that includes a
die having a nozzle row, the nozzle row extruding a thermoplastic
resin, a resin supply means supplying the thermoplastic resin to
the die, a hot air supply means supplying hot air to the
thermoplastic resin extruded from the nozzle row of the die to draw
the thermoplastic resin into fibers, and a collector having a
conveyor belt, the collector collecting the thermoplastic resin
that has been drawn into fibers to form a web by the self-fusion
property, wherein the die is disposed in such a manner that the
angle of the die can be changed in a direction inclined relative to
a width direction of the web that is perpendicular to a moving
direction of the conveyor belt so that a width dimension of the web
to be formed can be adjusted to a dimension corresponding to the
angle of the die.
[0012] A resin inflow port of the die is preferably turnably
attached to a resin supply port of the resin supply means so that
the angle of the die can be changed by adjusting a turning angle of
the attachment.
[0013] Specifically, an attachment structure between the resin
inflow port of the die and the resin supply port of the resin
supply means is preferably a butt connection structure between
flanges and the flanges can be fixed to each other with changing an
angle therebetween.
[0014] Preferably, the flanges can be fixed to each other with
changing the angle therebetween using a quick coupling.
[0015] The die is preferably provided with slits as the hot air
supply means through which hot air is blown out from both sides
across the nozzle row.
[0016] Preferably, the collector includes a mesh-like conveyor belt
and a suction box that sucks air on an upper surface of the belt
from a rear surface of the belt, and at least a suction unit of the
suction box that faces the die across the conveyor belt is disposed
in such a manner that the angle thereof can be changed to a
direction inclined relative to the web width direction that is
perpendicular to the conveyor belt moving direction.
[0017] In particular, the nonwoven fabric manufacturing apparatus
preferably includes an interlocking mechanism that changes at least
the angle of the suction unit of the suction box in interlocking
with angle change of the die.
[0018] Further, the present invention also provides a nonwoven
fabric manufacturing apparatus in which a resin inflow port of a
die having a nozzle row that extrudes a thermoplastic resin is
turnably attached to a resin supply port of a resin supply means,
wherein an expansion portion having an outer peripheral surface
whose diameter expands toward a tip in a fan shape is provided in
one of the resin inflow port and the resin supply port, a recessed
portion is provided in the other one of the resin inflow port and
the resin supply port, the recessed portion having an inner
peripheral surface whose diameter decreases toward a tip and
receiving the expansion portion inside thereof to allow the outer
peripheral surface to abut on the inner peripheral surface to
thereby lock the expansion portion relatively rotatably in a
circumferential direction as well as inseparably in an axial
direction, and the resin inflow port of the die is turnably
attached to the resin supply port of the resin supply means by a
support structure that includes the expansion portion and the
recessed portion.
[0019] The expansion portion is preferably formed on an outer
periphery of a tip of a joint tube that constitutes the resin
inflow port or an outer periphery of a tip of a resin supply tube
that constitutes the resin supply port.
[0020] The recessed portion preferably includes a flange that is
formed on an outer periphery of a tip of a resin supply tube that
constitutes the resin supply port or an outer periphery of a tip of
a joint tube that constitutes the resin inflow port and a holding
cylinder that is disposed in a protruding manner on a tip surface
of the flange and has the inner peripheral surface.
[0021] Preferably, the outer peripheral surface of the expansion
portion is formed in a conical surface and the inner peripheral
surface of the recessed portion is formed in a conical hole surface
that faces the outer peripheral surface in parallel thereto.
[0022] Further, the present invention also provides a nonwoven
fabric manufacturing apparatus in which a resin inflow port of a
die having a nozzle row that extrudes a thermoplastic resin is
turnably attached to a resin supply port of a resin supply means,
wherein one of the resin inflow port and the resin supply port
includes a cylindrical portion and an expansion portion having an
outer peripheral surface whose diameter expands on a tip of the
cylindrical portion, a holding body is provided in the other one of
the resin inflow port and the resin supply port, the holding body
having a recessed portion receiving the expansion portion inside
thereof to thereby lock the expansion portion relatively rotatably
in a circumferential direction as well as inseparably in an axial
direction, a cylindrical support portion is provided in a region on
a tip of the holding body, the cylindrical support portion having
an inner peripheral surface that is continuous with an inner
surface of the recessed portion and relatively rotatably supports
an outer peripheral surface of the cylindrical portion, and the
resin inflow port of the die is turnably supported with respect to
the resin supply port of the resin supply means by a support
structure that includes the expansion portion and the holding
body.
[0023] A bearing member is preferably interposed between the outer
peripheral surface of the cylindrical portion and the inner
peripheral surface of the cylindrical support portion.
[0024] A bearing member is preferably interposed between an outer
surface of the expansion portion, the outer surface facing a base
end side of the expansion portion, and an inner surface of the
recessed portion of the holding body, the inner surface facing a
base end side of the recessed portion and being opposed to the
outer surface of the expansion portion.
[0025] A seal member surrounding a resin flow path is preferably
disposed between an outer surface of the expansion portion, the
outer surface facing a tip side of the expansion portion, and an
inner surface of the recessed portion of the holding body, the
inner surface facing a tip side of the recessed portion and being
opposed to the outer surface of the expansion portion.
[0026] Preferably, the cylindrical portion is composed of a joint
tube that constitutes the resin inflow port or a resin supply tube
that constitutes the resin supply port, and the expansion portion
is formed on an outer periphery of a tip of the joint tube or an
outer periphery of a tip of the resin supply tube.
[0027] The holding body preferably includes a flange that is formed
on an outer periphery of a tip of a resin supply tube that
constitutes the resin supply port or an outer periphery of a tip of
a joint tube that constitutes the resin inflow port and a holding
cylinder that is disposed in a protruding manner on a tip surface
of the flange and has the recessed portion and the cylindrical
support portion continuous with the recessed portion.
[0028] Preferably, the outer peripheral surface of the expansion
portion is parallel to the outer peripheral surface of the
cylindrical portion, and the holding body includes a recessed
portion having an inner peripheral surface parallel to the outer
peripheral surface of the expansion portion and a cylindrical
support portion having an inner peripheral surface whose diameter
decreases in a stepwise manner continuously with the recessed
portion, the inner peripheral surface being parallel to the outer
peripheral surface of the cylindrical portion.
[0029] Further, the present invention also provides a nonwoven
fabric manufacturing method that includes preparing a nonwoven
fabric manufacturing apparatus including a die having a nozzle row,
the nozzle row extruding a thermoplastic resin, a resin supply
means supplying the thermoplastic resin to the die, a hot air
supply means supplying hot air to a thermoplastic resin extruded
from the nozzle row of the die to draw the thermoplastic resin into
fibers, and a collector having a conveyor belt, the collector
collecting the thermoplastic resin that has been drawn into fibers
to form a web by the self-fusion property; disposing the die in
such a manner that the angle of the die can be changed in a
direction inclined relative to a width direction of the web that is
perpendicular to a moving direction of the conveyor belt; and
adjusting a width dimension of the web to be formed to a dimension
corresponding to the angle of the die by changing the angle of the
die.
Advantageous Effects of Invention
[0030] According to the nonwoven fabric manufacturing apparatus and
the nonwoven fabric manufacturing method pertaining to the present
invention as described above, the die is disposed in such a manner
that the angle thereof can be changed in the direction inclined
relative to the width direction of the web that is perpendicular to
the moving direction of the conveyor belt so that the width
dimension of the web to be formed can be adjusted to a dimension
corresponding to the angle of the die. Therefore, it becomes first
possible to manufacture nonwoven fabrics having various widths
using the same die. As a result, it is possible to eliminate time
and cost for preparing various types of dies and replacing the dies
depending on the dimension, to cope with minute dimensional
differences, to omit dimensional adjustment by cutting, to largely
reduce manufacturing cost, and to manufacture uniform nonwoven
fabrics with no variation in dimension.
[0031] Further, the resin inflow port of the die is turnably
attached to the resin supply port of the resin supply means and the
angle of the die can be changed by adjusting a turning angle of the
attachment. Thus, even when the attachment angle of the die is
changed, no trouble occurs in supply of the resin. Further, a
desired space and cost can be achieved by a simple structure having
high efficiency.
[0032] Further, the attachment structure between the resin inflow
port of the die and the resin supply port of the resin supply means
is the butt connection structure between the flanges and the
flanges can be fixed to each other with changing an angle
therebetween. Thus, it is possible to hold the die in a stable
attitude also after changing the angle while maintaining sufficient
connection strength.
[0033] Further, the flanges can be fixed to each other with
changing the angle therebetween using the quick coupling. Thus, it
is possible to promptly perform the angle change operation.
[0034] Further, the die is provided with the slits as the hot air
supply means through which hot air is blown out from both sides
across the nozzle row. Thus, the angle of the slits for supplying
hot air is changed integrally with the nozzle row. Accordingly, it
is possible to supply hot air to an accurate position also after
the angle change.
[0035] Further, the collector includes the mesh-like conveyor belt
and the suction box that sucks air on the upper surface of the belt
from the rear surface of the belt, and at least the suction unit of
the suction box that faces the die across the conveyor belt is
disposed in such a manner that the angle thereof can be changed to
the direction inclined relative to the web width direction that is
perpendicular to the conveyor belt moving direction. Thus, it is
possible to reliably suck hot air from the die and an accompanied
flow thereof also after changing the angle of the die and thereby
stably obtain uniform nonwoven fabrics.
[0036] Further, the interlocking mechanism that changes at least
the angle of the suction unit of the suction box in interlocking
with angle change of the die is provided. Thus, it is possible to
largely reduce operation burden/operation time.
[0037] Further, the expansion portion having the outer peripheral
surface whose diameter expands toward the tip in a fan shape is
provided in one of the resin inflow port and the resin supply port,
and the recessed portion is provided in the other one of the resin
inflow port and the resin supply port, the recessed portion having
the inner peripheral surface whose diameter decreases toward the
tip and receiving the expansion portion inside thereof to allow the
outer peripheral surface to abut on the inner peripheral surface to
thereby lock the expansion portion relatively rotatably in the
circumferential direction as well as inseparably in the axial
direction. Further, the resin inflow port of the die is turnably
attached to the resin supply port of the resin supply means by a
support structure that includes the expansion portion and the
recessed portion. Thus, it is possible to rotate the die without
generating a gap between the joined surfaces. Further, it is not
necessary to previously remove the resin inside thereof before the
angle change. Further, it is possible to promptly perform the
operation and obtain nonwoven fabrics having different widths
without reducing the productivity.
[0038] Further, the outer peripheral surface of the expansion
portion is formed in a conical surface and the inner peripheral
surface of the recessed portion is formed in a conical hole surface
that faces the outer peripheral surface in parallel thereto. Thus,
it is possible to hold the die in a stable attitude also after
changing the angle thereof while maintaining sufficient connection
strength.
[0039] Further, one of the resin inflow port and the resin supply
port includes the cylindrical portion and the expansion portion
having the outer peripheral surface whose diameter expands on the
tip of the cylindrical portion, and the holding body is provided in
the other one of the resin inflow port and the resin supply port,
the holding body having the recessed portion receiving the
expansion portion inside thereof to thereby lock the expansion
portion relatively rotatably in the circumferential direction as
well as inseparably in the axial direction. Thus, it is not
necessary to previously remove the resin inside thereof before the
angle change. Further, it is possible to promptly perform the
operation and obtain nonwoven fabrics having different widths
without reducing the productivity. Further, the cylindrical support
portion is provided in the region on the tip of the holding body,
the cylindrical support portion having the inner peripheral surface
that is continuous with the inner surface of the recessed portion
and relatively rotatably supports the outer peripheral surface of
the cylindrical portion. Thus, the cylindrical support portion and
the cylindrical portion support each other when the die rotates,
thereby preventing the die from being inclined. Therefore, for
example, even when a rotational force is applied to the die from
one end thereof, the axes of the die and the resin inflow port are
not inclined relative to the resin supply port. Accordingly, it is
possible to allow the die to smoothly rotate in a stable state and
also to prevent seizure caused by the end of the upper surface of
the expansion portion partially making contact with the flange or
the recessed portion. As a result, it is possible to provide an
apparatus having excellent usability and maintaining the
flexibility of design.
[0040] Further, the bearing member is interposed between the outer
peripheral surface of the cylindrical portion and the inner
peripheral surface of the cylindrical support portion. Thus, it is
possible to more stably and smoothly rotate the die.
[0041] Further, the bearing member is interposed between the outer
surface of the expansion portion, the outer surface facing the base
end side of the expansion portion, and the inner surface of the
recessed portion of the holding body, the inner surface facing the
base end side of the recessed portion and being opposed to the
outer surface of the expansion portion. Thus, it is possible to
more stably and smoothly rotate the die having a heavy weight.
[0042] Further, the seal member surrounding the resin flow path is
disposed between the outer surface of the expansion portion, the
outer surface facing the tip side of the expansion portion, and the
inner surface of the recessed portion of the holding body, the
inner surface facing the tip side of the recessed portion and being
opposed to the outer surface of the expansion portion. Thus, it is
not necessary to allow the expansion portion and the recessed
portion of the holding body to directly make contact with each
other to apply a seal function. Accordingly, the flexibility of
design is improved, and it is possible to simplify the structures
of the expansion portion and the holding body to reduce the
manufacturing cost.
[0043] Further, the cylindrical portion is composed of the joint
tube that constitutes the resin inflow port or the resin supply
tube that constitutes the resin supply port, and the expansion
portion is formed on the outer periphery of the tip of the joint
tube or the outer periphery of the tip of the resin supply tube.
Thus, it is possible to achieve a rational structure, to reduce the
number of components, and to reduce the cost.
[0044] Further, the holding body includes the flange that is formed
on the outer periphery of the tip of the resin supply tube that
constitutes the resin supply port or the outer periphery of the tip
of the joint tube that constitutes the resin inflow port and the
holding cylinder that is disposed in a protruding manner on the tip
surface of the flange and has the recessed portion and the
cylindrical support portion continuous with the recessed portion.
Thus, the assembly is easily performed, the flexibility of design
is improved, and the manufacturing cost can be reduced.
[0045] Further, the outer peripheral surface of the expansion
portion is parallel to the outer peripheral surface of the
cylindrical portion, and the holding body includes the recessed
portion having the inner peripheral surface parallel to the outer
peripheral surface of the expansion portion and the cylindrical
support portion having the inner peripheral surface whose diameter
decreases in a stepwise manner continuously with the recessed
portion, the inner peripheral surface being parallel to the outer
peripheral surface of the cylindrical portion. Thus, the structure
is simplified, no high-accuracy machining is required, and lower
cost can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIG. 1 is an explanatory diagram illustrating a nonwoven
fabric manufacturing apparatus according to a first embodiment of
the present invention.
[0047] FIG. 2(a) is an explanatory diagram illustrating a state of
manufacturing a nonwoven fabric with a die of the nonwoven fabric
manufacturing apparatus facing a direction perpendicular to a
conveyor belt moving direction and FIG. 2(b) is an explanatory
diagram illustrating a state of manufacturing a nonwoven fabric
with the die inclined by a predetermined angle .theta. from the
direction perpendicular to the conveyor belt moving direction.
[0048] FIG. 3(a) is a plan view illustrating an attachment
structure between a resin inflow port of the die and a resin supply
port of a resin supply means and FIG. 3(b) is a vertical
cross-sectional view thereof.
[0049] FIG. 4(a) is a plan view illustrating a modification of the
attachment structure and FIG. 4(b) is a vertical cross-sectional
view thereof.
[0050] FIG. 5 is an explanatory diagram illustrating a nonwoven
fabric manufacturing apparatus according to a second embodiment of
the present invention.
[0051] FIG. 6(a) is an explanatory diagram illustrating a state of
manufacturing a nonwoven fabric with a die of the nonwoven fabric
manufacturing apparatus and a suction unit of a suction box that
faces the die both facing a direction perpendicular to a conveyor
belt moving direction and FIG. 6(b) is an explanatory diagram
illustrating a state of manufacturing a nonwoven fabric with the
die and the suction unit of the suction box inclined by a
predetermined angle .theta. from the direction perpendicular to the
conveyor belt moving direction.
[0052] FIG. 7 is an explanatory diagram illustrating a support
structure according to a third embodiment of the present
invention.
[0053] FIG. 8 is a vertical cross-sectional view illustrating a
principal part of the support structure which includes an expansion
portion and a recessed portion.
[0054] FIG. 9 is an explanatory diagram illustrating a modification
of the support structure.
[0055] FIG. 10 is a schematic view of a nonwoven fabric
manufacturing apparatus according to a fourth embodiment of the
present invention viewed from the front thereof, the nonwoven
fabric manufacturing apparatus being provided with an auxiliary
mechanism which rotates a die.
[0056] FIG. 11 is a schematic view of the nonwoven fabric
manufacturing apparatus viewed from the lateral side thereof.
[0057] FIG. 12 is a schematic view illustrating another example of
the nonwoven fabric manufacturing apparatus provided with the
auxiliary mechanism which rotates the die.
[0058] FIGS. 13(a) and 13(b) are explanatory diagrams illustrating
a state in which an axis is inclined in the third embodiment.
[0059] FIGS. 14(a) and 14(b) are vertical cross-sectional views
illustrating a principal part of a support structure which includes
an expansion portion and a recessed portion according to a fifth
embodiment of the present invention.
[0060] FIG. 15 is a vertical cross-sectional view illustrating a
modification of the support structure.
[0061] FIG. 16 is a vertical cross-sectional view illustrating
another modification of the support structure.
[0062] FIG. 17 is a schematic view illustrating a melt-blown
method.
REFERENCE SIGNS LIST
[0063] A Attachment structure (support structure) [0064] 1 Nonwoven
fabric manufacturing apparatus [0065] 2 Die [0066] 2a Pin hole
[0067] 3 Resin supply means [0068] 3a Cylindrical portion [0069] 4a
Cylindrical portion [0070] 5 Collector [0071] 6 Rotary positioning
device [0072] 6A Turning device [0073] 7 Holding body [0074] 8 Hot
air supply means [0075] 10 Molten resin flow [0076] 11 Conveyor
(belt) [0077] 12 Nonwoven fabric (web) [0078] 13 Gap [0079] 14
Frame [0080] 15 Hanging tool [0081] 16 Hanging tool support device
[0082] 20 Nozzle row [0083] 21 Resin inflow port [0084] 21a Fine
hole [0085] 23 Flange [0086] 23a Screw hole [0087] 30 Extruder
[0088] 31 Resin supply port [0089] 32 Recessed portion [0090] 32b
Inner peripheral surface [0091] 32c Inner surface [0092] 32d Inner
surface [0093] 33 Bolt [0094] 34 Washer [0095] 35 Nut [0096] 36
Filter [0097] 37 Gear pump [0098] 38 Support pipe portion [0099] 39
Flange [0100] 39b Long hole [0101] 40 Joint tube [0102] 41
Expansion portion [0103] 41a Outer peripheral surface [0104] 41c
Outer surface [0105] 41d Outer surface [0106] 41e Annular groove
[0107] 50 Resin supply tube [0108] 51 Flange [0109] 51d Bolt
insertion hole [0110] 52 Holding cylinder [0111] 52c Recessed
groove [0112] 52d Through hole [0113] 53, 54 Conveyor roller [0114]
55 Drive roller [0115] 56 Guide roller [0116] 57 Tension roller
[0117] 61 Engagement member [0118] 61b Pin [0119] 62 Turning device
[0120] 62a Rotary table [0121] 63 Lifting device [0122] 64 Rotary
component [0123] 70 Cylindrical support portion [0124] 70a Inner
peripheral surface [0125] 71, 72 Bearing member [0126] 73 Seal
member [0127] 80 Bolt [0128] 81 Ring [0129] 82 Ring groove [0130]
83 Quick coupling [0131] 84 Clamp [0132] 84c Recessed groove [0133]
85 Eyebolt [0134] 86 Wing nut [0135] 140 Compressor [0136] 141
Heater [0137] 151 Calender roll [0138] 152 Winder [0139] 170, 170A,
170B, 171 Suction box [0140] 170a Support cylinder [0141] 172, 173
Blower
DESCRIPTION OF EMBODIMENTS
[0142] Next, embodiments of the present invention will be described
in detail with reference to the accompanying drawings.
[0143] First, a first embodiment of the present invention will be
described with reference to FIGS. 1 to 4(b).
[0144] As illustrated in FIGS. 1, 2(a), and 2(b), a nonwoven fabric
manufacturing apparatus 1 of the present embodiment is a melt-blown
nonwoven fabric manufacturing apparatus which is provided with a
die 2 having a nozzle row 20 which extrudes a molten polymer
(thermoplastic resin), a resin supply means 3 which supplies a
molten polymer to the die 2, a hot air supply means 8 which
supplies hot air to the molten polymer extruded from the nozzle row
20 of the die 2 to thereby draw the molten polymer into fibers, a
collector 5 which has a conveyor belt 11 and collects the molten
polymer that has been drawn into fibers to form a nonwoven fabric
web 12 by the self-fusion property thereof. In particular, the die
2 is disposed in such a manner that the angle thereof can be
changed in a direction inclined relative to a web width direction
that is perpendicular to a moving direction of the conveyor belt
11. The width dimension of the web 12 to be formed is adjusted to a
dimension corresponding to the angle of the die 2.
[0145] The die 2 of this example is a T-die for uniformly
distributing a molten polymer from a resin inflow port 21 toward
the nozzle row 20 from which the molten polymer is extruded. The
die 2 constitutes a spin head which has air slits (not illustrated)
formed on both sides of the nozzle row 20 and hot air is blown out
through the air slits. The present invention is not limited at all
to the die having such a structure. The nozzle row 20 has many fine
holes 20a which are arrayed side by side in a direction
perpendicular to the cross section of the die 2. The hot air slits
(blowout ports, not illustrated) are formed on both sides of the
fine holes 20a in parallel to the nozzle row 20. Although an
example in which a single nozzle row 20 is arranged is illustrated
in this example, a plurality of nozzle rows may, of course, be
arranged.
[0146] A molten polymer extruded through each of the fine holes 20a
of the nozzle row 20 is drawn with hot air which is blown out at
high speed from the slits on both sides so as to sandwich an exit
of each of the fine holes 20a and formed into fine fibers. In this
manner, the molten polymer is extruded through each of the fine
holes 20a and drawn into fibers, and collected on the conveyor belt
11 of the collector 5 to form the nonwoven fabric web 12.
[0147] The resin supply means 3 includes an extruder 30 which melts
and extrudes a polymer (thermoplastic resin), a filter 36 which
removes foreign substances, a gear pump 37 for continuously feeding
a specified amount of molten polymer to the die 2, and a support
pipe portion 38 which has a resin supply port 31 which is formed on
an end of the support pipe portion 38 and connected to the resin
inflow port 21 of the die 2 to attach the die 2 thereto. The resin
inflow port 21 of the die 2 is turnably attached to the resin
supply port 31 of the support pipe portion 38. The angle of the die
2 can be adjusted as illustrated in FIGS. 2(a) and 2(b) by changing
the turning angle of the attachment.
[0148] As illustrated in FIGS. 3(a) and 3(b), an attachment
structure A of the turnable die 2 is a butt connection structure
between a flange 23 of the resin inflow port 21 and a flange 39 of
the resin supply port 31. Specifically, a long hole 39b having a
length in a predetermined angle range along the circumferential
direction is formed on the flange 39 on one side and a screw hole
23a with which a bolt (a bolt with a hexagonal hole) 80 inserted
through the long hole 39b is screwed is formed on the flange 23 on
the other side. Accordingly, the angle change is completed merely
by loosening the bolt 80, then rotating the die 2 by a necessary
angle, and then tightening the bolt 80. In this example, four sets
of long holes 39b and screw holes 23a are formed at equal
positions. However, the number of sets is not particularly limited.
An O-ring 81 is attached to the inside of an O-ring groove 82 at a
position closer to the inner peripheries of the flanges 23, 39 so
as to prevent leakage of the molten polymer. As can be easily
conceived, it is possible to perform the angle change by an
operation within an extremely short time.
[0149] As described above, in this example, the die 2 is turnably
supported by the support pipe portion 38 which has the resin supply
port 31 of the resin supply means 3. However, the present invention
is not limited at all to such a support structure. The resin supply
port 31 of the resin supply means 3 may be turnable together with
the die, and the structure which turnably supports the die 2 may be
composed of a support body which is independent of the resin supply
means 3. Further, in this example, the support structure turnably
supports the resin inflow port 21 which is formed on the central
part of the die 2 so as to turn around the central part. However,
the resin inflow port 21 is not necessarily turnable around the
central part, and is also preferably turnably supported around a
deviated position or an end position. In particular, supporting the
die 2 by the support body independent of the resin supply means 3
as described above enhances the flexibility of design.
[0150] As another example of the attachment structure A, as
illustrated in FIGS. 4(a) and 4(b), the flange 23 and the flange 39
are fixed to each other with a quick coupling 83 instead of the
bolt. Accordingly, it is possible to perform the angle change by an
operation within a shorter time. That is, it is preferred to
configure the quick coupling 83 in such a manner that the outer
peripheral end surfaces of the respective flanges 23, 39 are each
formed to have a conical structure so as to be tapered surfaces
whose diameters gradually increase toward a joint side, and a clamp
84 which has a recessed groove 84c on the inner peripheral side
thereof, the recessed groove 84c being formed of tapered surfaces
parallel to the tapered surfaces of the flanges and having a
generally V shape, and covers the outer peripheral end surfaces of
both of the joined flanges from the outer side thereof is fastened
with an eyebolt 85 and a wing nut 86.
[0151] Also in this case, similarly, the O-ring 81 is attached to
the inside of the O-ring groove 82 at a position closer to the
inner peripheries of the flanges 23, 39 so as to prevent leakage of
the molten polymer. In order to change the angle of the die (spin
head) 2, it is only required to slightly loosen the wing nut 86 of
the clamp 84, then rotate the die 2 by a necessary angle, and then
fasten the wing nut 86. This is an operation within an extremely
short time. In addition, various structures such as a structure
capable of automatically controlling the turning angle using a gear
and a motor can be employed.
[0152] A known system can be employed as the hot air supply means
8. In this example, as illustrated in FIG. 1, the hot air supply
means 8 includes a heater 141 which is disposed in the middle of a
pipe which connects a compressor 140 and the die 2 to each other
and the slits (not illustrated) through which hot air is blown out
from both sides across the nozzle row 20 of the die 2. The angle of
the slits is changed integrally with the nozzle row 20 together
with the die 2.
[0153] The collector 5 includes the mesh-like conveyor belt 11 and
suction boxes 170, 171 which suck air on the upper surface side of
the belt from the rear surface side thereof. The molten polymer
extruded from the nozzle row 20 of the die 2 is drawn by hot air
from the slits so as to be formed into fiber flows and collected on
the conveyor belt 11. The conveyor belt 11 runs in a direction
indicated by arrows by a drive roller 55, a guide roller 56, a
tension roller 57, and conveyor rollers 53, 54. Thus, the polymer
fiber flows collected on the conveyor belt 11 under the die 2 are
formed into the nonwoven fabric web 12. The formed web 12 is
discharged from the collector 5, passes through a calender roll
151, and is wound up by a winder 152.
[0154] The suction boxes 170, 171 are provided for reliably
collecting the fiber flows on the conveyor belt 11 and cooling the
collected fiber flows. The suction boxes 170, 171 suck air
respectively by blowers 172, 173. In particular, the blower 172
which is powerful is connected to the suction box 170 in order to
suck hot air and an accompanied flow thereof right under the die
2.
[0155] According to the present embodiment, as illustrated in FIG.
2(a), the width of the nonwoven fabric web 12 that is manufactured
with the nozzle row 20 of the die 2 facing the direction
perpendicular to the conveyor belt moving direction is a width
dimension w0 that is substantially equal to the length of the
nozzle row. On the other hand, as illustrated in FIG. 2(b), when
the nozzle row 20 is inclined by the predetermined angle .theta.
from the direction perpendicular to the conveyor belt moving
direction, although the fiber flows drop on the conveyor belt 11
through the respective fine holes 20a of the nozzle row 20 having
the same length as above case, a width dimension w1 of the nonwoven
fabric web 12 to be obtained is approximately w0.times.cos .theta..
Thus, it is possible to obtain a nonwoven fabric having a width
narrower than the length of the nozzle row 20. In this manner, it
is possible to obtain various nonwoven fabrics using the same die 2
by changing the angle of the die 2 (spin head) relative to the
running direction of the conveyor belt 11.
[0156] Regarding the property of a nonwoven fabric to be
manufactured, when the amount of molten polymer extruded from the
nozzle row 20 of the die 2 is the same, the weight per unit area
(fabric weight) increases in the case of FIG. 2(b) compared to the
case of FIG. 2(a) by an amount corresponding to a reduction in the
width-direction dimension. Therefore, in order to obtain nonwoven
fabrics having the same fabric weight, but having different
dimensions, it is only required to adjust the amount of molten
polymer to be extruded.
[0157] Next, a second embodiment will be described with reference
to FIGS. 5, 6(a), and 6(b).
[0158] In the present embodiment, a suction box that faces a die 2
across a conveyor belt 11 includes a suction side suction box 170A
and an exhaust side suction box 170B. The suction side suction box
170A which serves as a suction unit is supported on the exhaust
side suction box 170B in such a manner that the angle thereof can
be changed in a direction inclined relative to the web width
direction like the die 2 described above.
[0159] Typically, the dimension of a suction port of the suction
box 170 right under the nozzle row 20 is 50 mm to 75 mm in the
front and back of the nozzle row, that is, 100 mm to 150 mm in the
vertical direction along the conveyor belt moving direction and the
length of the nozzle row plus several tens mm in the horizontal
direction along the web width direction perpendicular to the
conveyor belt moving direction. However, in the present invention,
the angle of the die 2 is changed. Thus, the suction box 170 is
required to have a larger size that can cover the angle range of
the die 2. Accordingly, the blower 172 is also required to have a
large suction force.
[0160] On the other hand, when the angle of the suction side
suction box 170A can be adjusted corresponding to the angle of the
die 2 as in the present embodiment, it is possible to reliably suck
hot air for drawing a polymer and the accompanied flow thereof even
with the minimum dimension corresponding to the dimension of the
die to obtain uniform nonwoven fabrics, and also to prevent an
increase in the size of the blower 172.
[0161] In this example, the suction side suction box 170A is
provided inside a larger suction box 171 in a twofold manner. The
suction side suction box 170A is turnably attached to a bottom wall
of the suction box 171 through a support cylinder 170a located on
the lower end of the suction side suction box 170A so as to turn
around the support cylinder 170a. The support cylinder 170a
penetrates the bottom wall of the suction box 171 and projects to
an internal space of the exhaust side suction box 170B arranged on
the lower side. An internal space of the suction side suction box
170A and the internal space of the exhaust side suction box 170B
communicate with each other through the support cylinder 170a. The
blower 172 is connected to the exhaust side suction box 170B. The
suction side suction box 170A is preferably provided with an
interlocking mechanism which automatically turns by the same angle
in interlocking with the angle change of the die 2.
[0162] Next, a third embodiment will be described with reference to
FIGS. 7 to 9.
[0163] The means for rotating the die in the above first embodiment
is the butt connection structure between the flanges as the
attachment structure between the resin inflow port of the die and
the resin supply port of the resin supply means as illustrated in
FIGS. 3(a), 3(b) and 4(a), 4(b). In such a structure, when the
flange connection is loosened, a gap is formed between the joined
surfaces. Thus, it is necessary to remove a resin inside thereof
before loosening the flange connection. These operations require
time. As a result, a certain limit may be generated in improvement
of the productivity.
[0164] In view of the above, the present embodiment improves the
above situation. FIG. 7 is a schematic view illustrating connection
between a resin inflow port 21 of a die 2 and a resin supply port
31 of a resin supply means 3 according to a nonwoven fabric
manufacturing apparatus 1 of the present invention. A support
structure A which turnably supports the resin inflow port 21 of the
die 2 with respect to the resin supply port 31 of the resin supply
means 3 is provided between the tip of a joint tube 40 which
constitutes the resin inflow port 21 and the tip of a resin supply
tube 50 which constitutes the resin supply port 31.
[0165] As illustrated in FIG. 8, the support structure A of the
present embodiment includes an expansion portion 41 which is formed
on the resin inflow port 21 and a recessed portion 32 which is
formed on the resin supply port 31 and coaxially receives the
expansion portion 41. The expansion portion 41 has an outer
peripheral surface 41a whose diameter expands toward the tip of the
resin inflow port 21 in a fan shape. Specifically, the expansion
portion 41 is integrally formed with the outer periphery of the tip
of the joint tube 40 which constitutes the resin inflow port
21.
[0166] The recessed portion 32 has an inner peripheral surface 32b
whose diameter decreases toward the tip, and receives the expansion
portion 41 inside thereof to allow an outer peripheral surface 41a
of the expansion portion 41 to abut on the inner peripheral surface
32b to thereby lock the expansion portion 41 relatively rotatably
in the circumferential direction as well as inseparably in the
axial direction. Specifically, the recessed portion 32 includes a
flange 51 which is formed on the outer periphery of the tip of the
resin supply tube 50 which constitutes the resin supply port 31 and
a holding cylinder 52 which is disposed in a protruding manner on
the tip surface of the flange 51 and has the inner peripheral
surface 32b.
[0167] The outer peripheral surface 41a of the expansion portion 41
is formed in a conical surface. The inner peripheral surface 32b of
the recessed portion 32 is formed in a conical hole surface which
faces the outer peripheral surface 41a in parallel thereto.
Accordingly, the outer peripheral surface 41a and the inner
peripheral surface 32b are closely joined to each other throughout
the entire circumferences and the entire surfaces. In addition, a
sufficient pressure joining force acts between the outer peripheral
surface 41a and the inner peripheral surface 32b by the self-weight
of the die. Thus, even if a resin flows into a gap 13 between the
tip surface of the expansion portion 41 and the tip surface of the
flange 51, the resin does not leak out.
[0168] The holding cylinder 52 is a holding fitting made of metal
in which a recessed groove 52c which receives the flange 51 so as
to be fitted thereto is formed on a surface on the base end side
and a through hole 52d which corresponds to a bolt insertion hole
51d of the flange 51 is formed to communicate with the bolt
insertion hole 51d in the axial direction. The holding cylinder 52
is fixed to the flange 51 with the bolt 33 which passes through the
bolt insertion hole 51d and the thorough hole 52d, the washer 34,
and the nut 35 with the holding cylinder 52 attached to the outer
peripheral part of the expansion portion 41. Accordingly, the
expansion portion 41 is inseparably locked inside the formed
recessed portion 32.
[0169] Theoretically, the gap 13 between the tip surface of the
expansion portion 41 and the tip surface of the flange 51 may not
be formed. However, if these tip surfaces come into close contact
with each other, the expansion portion 41 cannot turn in the
circumferential direction with respect to the recessed portion 32.
As a result, it is necessary to loosen the bolt 33, and the resin
may thereby leak out. Thus, a degree of close contact that enables
the expansion portion 41 to turn with the bolt 33 fastened is
required. In order to generate a joint state having such a delicate
degree of close contact, machining with high accuracy is required.
Thus, it is actually preferred to actively form the gap 13 to
prevent the nonexistence of the gap 13 causing a close contact
state which makes the expansion portion 41 unturnable even with a
low machining accuracy.
[0170] The resin flows into the gap 13. However, the expansion
portion outer peripheral surface 41a and the recessed portion inner
peripheral surface 32b are joined to each other by pressure as
described above, and it is therefore possible to prevent the
outflow of the resin by virtue of these surfaces which serve as a
seal. In order to achieve more reliable seal effect, it is desired
to perform lapping on the outer peripheral surface 41a and the
inner peripheral surface 32b. Further, a packing, for example, a
heat-resistant resin is desirably disposed in the gap 13 in an
uncrushed state at ordinary temperature. The packing has a larger
thermal expansion coefficient than metal, for example, the
connection tube. Thus, the packing is expected to reliably seal the
gap 13 to stop the resin in an operating state in which the
temperature increases.
[0171] In the present embodiment, the expansion portion 41 is
provided in the resin inflow port 21 and the recessed portion 32 is
provided in the resin supply port 31 as the support structure A.
However, as illustrated in FIG. 9, conversely, a similar recessed
portion may be provided in the resin inflow port 21 and a similar
expansion portion may be provided in the resin supply port 31. In
this case, the recessed portion 32 on the die is supported on the
outer peripheral surface of the expansion portion on the resin
supply means 3 inseparably in the axial direction as well as
turnably in the circumferential direction.
[0172] In the present embodiment, the outer peripheral surface 41a
of the expansion portion 41 is formed in a conical surface and the
inner peripheral surface 32b of the recessed portion 32 is formed
in a conical hole surface parallel to the outer peripheral surface
41a. However, the outer peripheral surface of the expansion portion
may be formed in a curved surface whose diameter expansion ratio
varies, for example, an outwardly convex spherical surface in
addition to the conical surface whose diameter expands at a
constant ratio along the axial direction as described above as long
as the diameter of the outer peripheral surface expands in a fan
shape. Similarly, the inner peripheral surface of the recessed
portion may be formed in a curved surface whose diameter reduction
ratio varies, for example, an inwardly convex spherical surface in
addition to the conical hole surface whose diameter decreases at a
constant ratio as long as the diameter of the inner peripheral
surface decreases toward the tip.
[0173] In curved surfaces other than a conical surface or a conical
hole surface, it is difficult to have a sufficient machining
accuracy. Thus, when such curved surfaces are employed, it is
preferred to set the outer peripheral surface of the expansion
portion to have a smaller curvature along the axial direction than
the inner peripheral surface of the recessed portion without
setting the curved surfaces parallel to each other. Further, it is
more preferred that only the outer peripheral surface of the
expansion portion be formed in a curved surface other than the
conical surface, for example, an outwardly convex spherical surface
and the inner peripheral surface of the recessed portion be formed
in a conical hole surface having a constant diameter reduction
ratio in the same manner as the above embodiment.
[0174] Next, a fourth embodiment will be described with reference
to FIGS. 10 to 12.
[0175] The die 2 typically has a large weight. Therefore, the die 2
cannot be supported only by the support structure A in some cases.
Thus, in the present embodiment, as illustrated in FIGS. 10 and 11,
the die 2 is additionally supported by a hanging tool 15 from a
frame 14 located above the die 2. The hanging tool 15 is supported
on the frame 14 through a rotatable hanging tool support device 16
and capable of rotating in interlocking with turn of the die 2.
[0176] The die 2 can be manually rotated by a necessary angle by
the structure of the support structure A. However, the temperature
of the die 2 is 200 to 350.degree. C. and therefore high. In
addition, when the weight of the die 2 is large, a considerable
force is also required. Thus, the rotation of the die 2 is
preferably mechanically performed because of safety reasons. As an
auxiliary mechanism which rotates the die 2, a mechanism which
rotates the die 2 from the lower side will be first described.
[0177] As illustrated in FIGS. 10 and 11, the mechanism rotates the
die 2 by setting a rotary positioning device 6 which is engaged
with the die 2 to rotate the die 2 by a predetermined angle under
the die 2. The rotary positioning device 6 is provided with an
engagement member 61 and a rotary table 62a. A pin 61b which is
engaged with a pin hole 2a formed on the die 2 is disposed in a
protruding manner on the upper surface of the engagement member 61.
The engagement member 61 is fixed to the upper surface of the
rotary table 62a. In addition, the rotary positioning device 6
further includes a turning device 62 which turns the rotary table
by any angle and a lifting device 63 which moves the turning device
62 up and down together with the engagement member 61.
[0178] When rotating the die 2 using the rotary positioning device
6, the rotary positioning device 6 is first set under the die 2 in
a manner to align the turning center axis of the rotary table 62a
with the turning center axis of the support structure of the die 2
in a state engaged with the die 2, and the turning device 62 is
then turned and stopped at a position where the angle position of
the pin hole 2a of the die 2 matches the angle position of the pin
61b of the engagement member 61 and the pin hole 2a and the pin 61b
are thereby engaged with each other. Then, the lifting device 63
moves the turning device 62 upward together with the engagement
member 61 so that the pin hole 2a and the pin 61b are engaged with
each other. Then, the turning device 62 is turned by a necessary
angle to thereby turn and stop the die 2 through the pin 61b of the
engagement member 61. Then, the lifting device 63 moves the tuning
device 62 downward so that the rotary positioning device 6 is
detached or retracted from the lower side of the die 2.
[0179] The rotary positioning device 6 may be set under the die 2,
for example, by fixing the rotary positioning device 6 to a mount
or frame of the conveyor using an appropriate method. A turning
mechanism of the turning device 62 and a lifting mechanism of the
lifting device 63 may be manually driven or driven by a motor or
the like. As the turning device 62, for example, a rotary index can
be applied. In this example, the die 2 is auxiliary rotatably
supported through the hanging tool 15 and the hanging tool support
device 16. However, the hanging tool 15 and the hanging tool
support device 16 may be omitted.
[0180] Next, as the auxiliary mechanism which rotates the die 2, a
mechanism which rotates the die 2 from the upper side will be
described. As illustrated in FIG. 12, this method uses the hanging
tool 15 and the hanging tool support device 16. Further, the
mechanism includes a turning device 6A which turns the hanging tool
support device 16 together with the hanging tool 15. Specifically,
a rotary component 64, for example, a gear or a pulley is attached
to the upper end of the hanging tool support device 16 which is
rotatably attached to the frame 14 which supports the die 2.
Further, the rotary component 64 is driven to rotate by a
predetermined angle by a geared motor or a rotary index (not
illustrated). Accordingly, it is possible to allow the die 2 which
is hung by the hanging tool 15 to turn together with the hanging
tool 15 by a predetermined angle.
[0181] Next, a fifth embodiment will be described with reference to
FIGS. 13(a) to 16.
[0182] In the support structure A for rotating the die in the third
embodiment, the die is made rotatable while preventing leakage of
the resin by the lapping between the expansion portion 41 and the
inner peripheral surface of the recessed portion 32. In addition,
no seal member for preventing leakage of the resin is required.
However, in this attachment structure, for example, when a
rotational force is applied to the die from one end thereof for
rotating the die, the axes of the die 2 and the resin inflow port
21 are inclined relative to the axis of the resin supply port 31 as
illustrated in FIGS. 13(a) and 13(b). As a result, the end of the
upper surface of the expansion portion 41 partially makes contact
with the flange 51 or the recessed portion inner peripheral surface
32b, which may cause seizure. The rotation may be performed by
uniformly applying force so as to prevent the die and the resin
inflow port 21 from being inclined. However, limitation to such a
rotation applying mechanism causes poor usability, cost increase,
and reduction in the flexibility of design.
[0183] In view of the above, in the present embodiment, as
illustrated in FIGS. 14(a) and 14(b), a support structure A is
configured in such a manner that a cylindrical portion 4a (joint
tube 40) and an expansion portion 41 having an outer peripheral
surface 41a whose diameter expands on the tip of the cylindrical
portion 4a are provided in a resin inflow port 21, a holding body 7
which has a recessed portion 32 which coaxially receives the
expansion portion 41 is provided in a resin supply port 31, and a
cylindrical support portion 70 having an inner peripheral surface
which relatively rotatably supports the outer peripheral surface of
the cylindrical portion 4a is provided continuous with the inner
surface of the recessed portion 32 in a region on the tip side of
the holding body 7. The cylindrical portion 4a is composed of the
joint tube 40 which constitutes the resin inflow port 21. The
expansion portion 41 is integrally formed with the outer periphery
of the tip of the joint tube.
[0184] The holding body 7 includes a flange 51 which is formed on
the outer periphery of the tip of a resin supply tube 50 which
constitutes the resin supply port 31 and a holding cylinder 52
which is disposed in a protruding manner on the tip surface of the
flange 51 and has the recessed portion 32 and the cylindrical
support portion 70 continuous with the recessed portion 32. The
holding cylinder 52 is a holding fitting made of metal in which a
recessed groove 52c which receives the flange 51 so as to be fitted
thereto is formed on a surface on the base end side and a through
hole 52d which corresponds to a bolt insertion hole 51d of the
flange 51 is formed to communicate with the bolt insertion hole 51d
in the axial direction.
[0185] A bearing member 71 is interposed between the outer
peripheral surface of the cylindrical portion 4a and an inner
peripheral surface 70a of the cylindrical support portion 70. Also,
a bearing member 72 is interposed between an outer surface 41c of
the expansion portion 41, the outer surface 41c facing the base end
side of the expansion portion 41, and an inner surface 32c of the
recessed portion 32, the inner surface 32c facing the base end side
of the recessed portion 32 and being opposed to the outer surface
41c. A sufficient pressure joining force acts in this portion by
the self-weight of the die. Thus, the existence of the bearing
member 72 makes it possible to reliably prevent seizure. In the
present embodiment, the bearing members 71, 72 are composed of a
single member. However, the bearing members 71, 72 may be composed
of separate members. The bearing members 71, 72 are preferably
bushes (slide bearings) made of a material that is heat resistant
and not likely to cause seizure (metal or the like).
[0186] A seal member 73 which surrounds a resin flow path is
disposed between an outer surface 41d of the expansion portion 41,
the outer surface 41d facing the tip side of the expansion portion
41, and an inner surface 32d (the tip surface of the flange 51) of
the recessed portion 32, the inner surface 32d facing the tip side
of the recessed portion 32 and being opposed to the outer surface
41d. In the present embodiment, an annular groove 41e is formed on
the outer surface 41d of the expansion portion 41 and the annular
seal member 73 is engaged with and thereby attached to the annular
groove 41e. However, a similar annular groove to which the seal
member 73 is attached may, of course, be formed on the inner
surface 32d of the recessed portion 32.
[0187] A molten resin flows from the resin supply port 31 to the
resin inflow port 21 (joint tube 40). The seal member 73 prevents
the molten resin from leaking out to the outside. The seal effect
of the seal member 73 does not change even when the resin inflow
port 21 rotates relative to the resin supply port 31. As also
illustrated in FIG. 14(b), the seal member 73 is composed of one
called "C-ring", made of metal, for example, Inconel, and durable
against a high temperature of several hundred degrees. In the
drawing, DA denotes the outer diameter of the C-ring. The C-ring is
fitted into the annular groove 41e having an outer diameter (inner
diameter on the outer side) of D, a depth of G, and a width of
W.
[0188] The holding cylinder 52 with the bearing members 71, 72
attached to the inside thereof is fixed to the flange 51 with the
bolt 33 which passes through the bolt insertion hole 51d and the
through hole 52d, the washer 34, and the nut 35 with the holding
cylinder 52 attached to the outer peripheral part of the expansion
portion 41 with the seal member 73 attached to the outer surface
thereof and the outer peripheral part of the cylindrical portion
4a. Accordingly, there is maintained in a stable attitude in which
the expansion portion 41 is inseparably locked inside the formed
recessed portion 32 and the outer peripheral surface of the
cylindrical portion 4a is supported by the cylindrical support
portion 70 with the bearing member 71 interposed therebetween.
[0189] In the present embodiment, the outer peripheral surface 41a
of the expansion portion 41 is parallel to the outer peripheral
surface of the cylindrical portion 4a and formed in a flange shape.
Further, the recessed portion 32 has the inner peripheral surface
32b which is parallel to the outer peripheral surface 41a of the
expansion portion 41. The cylindrical support portion 70 has the
inner peripheral surface 70a whose diameter decreases in a stepwise
manner continuously with the recessed portion 32, the inner
peripheral surface being parallel to the outer peripheral surface
of the cylindrical portion 4a. As described above, the present
invention has a structure capable of supporting the cylindrical
portion 4a by the cylindrical support portion 70 to achieve
rotation of the die 2 in a stable attitude without causing axial
deflection as a whole. Further, a gap can be formed between the
outer peripheral surface 41a of the expansion portion 41 and the
inner peripheral surface 32b of the recessed portion 32. Thus, it
is easy to perform assembly between the resin inflow port 21 and
the resin supply port 31, specifically, assembly for attaching the
holding cylinder 52 to the outer peripheral part of the expansion
portion 41 and the outer peripheral part of the cylindrical portion
4a.
[0190] FIG. 15 illustrates a modification in which the expansion
portion 41 has an outer peripheral surface 41a whose diameter
expands toward the tip of the resin inflow port 21 in a fan shape.
A recessed portion 32 has an inner peripheral surface 32b whose
diameter decreases toward the tip. The recessed portion 32 receives
the expansion portion 41 inside thereof to allow the outer
peripheral surface 41a of the expansion portion 41 to abut on the
inner peripheral surface 32b to thereby lock the expansion portion
41 relatively rotatably in the circumferential direction as well as
inseparably in the axial direction. The outer peripheral surface
41a of the expansion portion 41 is formed in a conical surface. The
inner peripheral surface 32b of the recessed portion 32 is formed
in a conical hole surface which faces the outer peripheral surface
41a in parallel thereto. Accordingly, the outer peripheral surface
41a and the inner peripheral surface 32b are closely joined to each
other throughout the entire circumferences and the entire surfaces.
In addition, a sufficient pressure joining force acts between the
outer peripheral surface 41a and the inner peripheral surface 32b
by the self-weight of the die. Thus, even if a resin flows into a
gap 13 between the tip surface of the expansion portion 41 and the
tip surface of the flange 51, the resin does not leak out. Thus, it
is possible to omit the seal member 73.
[0191] The outer peripheral surface whose diameter expands in a fan
shape may be a curved surface whose diameter expansion ratio
varies, for example, an outwardly convex spherical surface in
addition to the conical surface whose diameter expands at a
constant ratio along the axial direction as described above.
Similarly, the inner peripheral surface of the recessed portion may
be formed in a curved surface whose diameter reduction ratio
varies, for example, an inwardly convex spherical surface in
addition to the conical hole surface whose diameter decreases at a
constant ratio as long as the diameter of the inner peripheral
surface decreases toward the tip. In curved surfaces other than a
conical surface or a conical hole surface, it is difficult to have
a sufficient machining accuracy. Thus, when such curved surfaces
are employed, it is preferred to set the outer peripheral surface
of the expansion portion to have a smaller curvature along the
axial direction than the inner peripheral surface of the recessed
portion without setting the curved surfaces parallel to each other.
Further, it is more preferred that only the outer peripheral
surface of the expansion portion be formed in a curved surface
other than the conical surface, for example, an outwardly convex
spherical surface and the inner peripheral surface of the recessed
portion be formed in a conical hole surface having a constant
diameter reduction ratio.
[0192] In the above embodiment, the expansion portion 41 is
provided in the resin inflow port 21 and the holding body 7 is
provided in the resin supply port 31 as the support structure A.
However, as illustrated in FIG. 16, conversely, a similar holding
body 7 may be provided in the resin inflow port 21 and a similar
expansion portion 41 may be provided in the resin supply port 31.
In this case, as illustrated in FIG. 16, the holding body 7 on the
die is supported on the outer peripheral surfaces of the expansion
portion 41 and a cylindrical portion 3a (resin supply tube 50) on
the resin supply means 3 inseparably in the axial direction as well
as turnably in the circumferential direction. Accordingly, when
rotating the die, the die is supported in a stable attitude without
causing inclination of the axis thereof.
[0193] The embodiments of the present invention have been described
above. However, the present invention is not limited at all to
theses embodiments. It is needless to say that the present
invention can be carried out in various forms without departing
from the scope of the invention.
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