JP4524138B2 - Cushion sheet, wave splitting processing apparatus, and wave splitting processing method - Google Patents

Description

  The present invention relates to a cushion sheet in which, for example, a urethane foam or the like is subjected to wave cutting processing including a plurality of convex portions and concave portions, and a wave cutting processing device used when wave cutting is applied to the cushion sheet. , And a wave splitting processing method.

  A conventional cushion sheet having a wave-cutting surface composed of peaks and valleys has a flat shape that is a simple flat plate as a whole. And as this kind of conventional wave splitting apparatus for producing such a cushion sheet, the thing of a structure as disclosed by patent document 1 is proposed, for example. That is, in this conventional configuration, a pair of rollers formed by alternately arranging a plurality of convex portions and concave portions on the outer peripheral surface along the circumferential direction and the axial direction are in a state where the concave and convex portions correspond to each other alternately. They are arranged in parallel. And by rotating both rollers, cushion sheets, such as urethane foam, are inserted between those rollers, and it sends in one direction, compressing between both uneven | corrugated | grooved parts. At this time, between the two rollers on the cushion sheet sending side, the cushion sheet before elastic restoration is cut and separated by the cutting blade, and the cutting surface side is subjected to wave cutting processing including a plurality of convex portions and concave portions, A cushion sheet is produced.

The two rollers are configured by fitting a plurality of discs formed by alternately arranging a plurality of convex portions and concave portions on the outer peripheral surface to the rotating shaft in a state of being superposed in the axial direction. A convex portion is formed on the outer peripheral surface of the rotating shaft, and a concave portion is formed in the fitting hole of each disk. By engagement between the convex portion and the concave portion, each disk is in contact with the rotating shaft. To be positioned at a predetermined position in the circumferential direction. Thereby, the uneven | corrugated | grooved part of both rollers is correctly arrange | positioned correspondingly in a staggered state.
JP 2002-283281 A

  By the way, in a cushion sheet used as a filler such as a bedding, a sheet, and a pillow, for example, the surface is formed in a substantially triangular wave shape including a plurality of convex portions and concave portions as described above, and a contact portion with a user's body. In addition to ensuring air permeability and the like between them, for example, it is required to improve the usability by forming the entire wave splitting surface into a curved shape so as to fit the user's body.

  Here, in the above-described conventional wave splitting device, the convex portions of both rollers are arranged in the circumferential direction and the axial direction of the rollers on the same cylindrical surface with the rotation axis of the rollers as the center. For this reason, when the cushion sheet is subjected to wave cutting with this processing apparatus, the entire wave cutting surface of the cushion sheet is formed in a flat flat surface and cannot be formed in a curved shape. It was.

  Further, conventionally, there is a cushion sheet that is configured by attaching a separate body in which a large number of ridges are formed on a thin sheet to the undulating surface of the base portion having the undulation. Has the disadvantages that it takes time and effort to stick, and the attached part is peeled off or the adhesive used for attaching makes a hard feel.

  The present invention has been made paying attention to such problems existing in the prior art. Its purpose is to apply a wave cutting process to a cushion sheet, and to change the entire wave cutting surface of the cushion sheet into a desired shape such as a curved shape. Is to provide.

In order to achieve the above object, in the invention according to claim 1 relating to the cushion sheet, in the cushion sheet in which the wave splitting surface composed of a plurality of peaks and valleys is formed on one side surface of the base portion, The base portion and the ridge portion are integrally formed, and the imaginary plane along the top of each ridge portion is formed so as to form an undulating surface, the difference between the ridge and the valley is constant, and the thickness of the base portion The virtual plane is undulated in one direction and a direction perpendicular thereto by changing the angle in one direction and a direction perpendicular thereto.

In the invention according to claim 2 , according to the wave splitting device, a pair of rollers formed by alternately arranging a plurality of convex portions and concave portions on the outer peripheral surface along the circumferential direction and the axial direction, Rotate these rollers in a state where they are arranged in parallel so as to correspond to each other, insert a cushion sheet between both rollers and feed it in one direction while compressing between both concave and convex parts, and sending out the cushion sheet In the wave cutting apparatus in which the cushion sheet before elastic restoration is cut and separated between both rollers on the side by cutting means and the cutting surface side is wave-cut, a plurality of protrusions provided on the both rollers Among the portions, the convex portions arranged on the same circumference are formed such that the height from the center of rotation continuously changes in the circumferential direction, and a plurality of convex portions provided on the both rollers. home The convex portions arranged on the same axial line are formed such that the height from the rotation center continuously changes in the axial direction, and the two rollers are the rotational centers of the convex portions in the circumferential direction and the axial direction. The height change patterns are arranged so as to be in opposite phases to each other .

According to a third aspect of the present invention, in the invention according to the second aspect, the two rollers have a plurality of discs in which a plurality of convex portions and concave portions are alternately arranged in the circumferential direction on the outer circumferential surface. The plurality of disks mounted on the same roller are configured in a similar direction, have a similar shape to each other, and have different diameters based on the outer peripheral edge of the convex portion, and the diameters along the axial direction are different. It is arranged so that it may change continuously .

The invention according to claim 4 according to the wave splitting method is a pair of rollers in which a plurality of convex portions and concave portions are alternately arranged on the outer peripheral surface along the circumferential direction and the axial direction. Among the plurality of convex portions provided on the convex portion, the convex portions arranged on the same circumference are formed such that the height from the rotation center continuously changes in the circumferential direction, and is provided on the roller. Among the plurality of protrusions, the protrusions arranged on the same axial line include a pair of rollers formed so that the height from the rotation center continuously changes in the axial direction. Both rollers are rotated in a state where they correspond to each other and are arranged in parallel so that the height change patterns from the rotation center of the convex portion in the circumferential direction and the axial direction are in opposite phases to each other. Insert a cushion sheet between While compressing between both concavo-convex parts, the sheet is fed in one direction, and the cushion sheet before elastic restoration is cut and separated by a cutting means between both rollers on the cushion sheet sending side, and the cutting surface side is subjected to wave cutting. It is characterized by that.
(Function)
In this invention, for at least one of the rollers, since the height of the convex portion from the roller rotation center is different from that of the other convex portion, when the wave splitting is performed on the cushion sheet by this processing device, The corrugated surface can be easily formed into a desired shape such as a curved shape in accordance with the change in the height of the convex portion on the roller. And when this processed cushion sheet is used as fillers, such as bedding, a sheet | seat, and a pillow, for example, a wave split processing surface can be fitted to a user's body and a usability can be improved.

  As described above, according to the present invention, when wave-cutting is performed on the cushion sheet, the wave-cut surface can be easily formed into a desired shape such as a curved shape, and the cushion has excellent usability. A sheet can be obtained.

(First embodiment)
Below, 1st Embodiment of this invention is described based on FIGS.
As shown in FIGS. 1 and 2, in the wave splitting device of this embodiment, the upper roller 11 and the lower roller 12 are disposed so as to be rotatable around parallel axes. On the outer peripheral surfaces of the rollers 11 and 12, a plurality of convex portions 13 and concave portions 14 constituting the concave and convex portions are alternately arranged at equal pitches along the circumferential direction and the axial direction. And the convex part 13 and the recessed part 14 on the upper roller 11 are positioned with respect to the convex part 13 and the recessed part 14 on the lower roller 12 so that it may respond | correspond alternately at those opposing approach parts.

  As shown in FIGS. 1 to 4, the rollers 11, 12 are fitted on the rotary shaft 16 in an outer fitting hole 15 a formed at the center of a plurality of discs 15 in the axial direction. Each pair of key screws 17 is fastened and fixed to the rotary shaft 16 for positioning. On the outer peripheral surface of each disk 15, the plurality of convex portions 13 and concave portions 14 are alternately arranged in a line in the circumferential direction.

  A motor (not shown) is connected to the rotating shafts 16 of the rollers 11 and 12 via a transmission mechanism (not shown) such as a gear. Then, both the rollers 11 and 12 are synchronously rotated in the direction of the arrow in FIG. 1 by this motor, so that the cushion sheet 18 such as urethane foam inserted between the rollers 11 and 12 is moved between the rollers 11 and 12. It is sent in the direction of the arrow in FIG. 1 while being compressed between the convex portion 13 and the concave portion 14. On the delivery side of the cushion sheet 18, a cutting blade 19 as a cutting means is disposed between the rollers 11 and 12. Then, the cutting blade 19 cuts and separates the cushion sheet 18 before elastic restoration, and a large number of triangular wave-shaped peaks 18a and valleys 18b are formed on the cut surface side of the base portion 18c, and wave cutting is performed. It has come to be.

  As shown in FIG. 2, the rollers 11 and 12 use a plurality of disks 15 having different diameters. However, in FIG. The diameter difference and the distance between the rollers 11 and 12 are exaggerated.

Next, the configuration of the rollers 11 and 12 and the arrangement configuration of the convex portions 13 and the concave portions 14 will be described in more detail.
In this embodiment, as shown in FIG. 4, the outer peripheral edge 13 a of each convex portion 13 arranged on the outer peripheral surface of the disk 15 of both rollers 11, 12 is from the rotation center P <b> 1 of the rollers 11, 12. It is configured to be located on one circumference centered on the eccentric position P2, and the height of the rollers 11, 12 from the rotation center P1 continuously changes. In order to obtain this configuration, for example, a plurality of protrusions 13 and recesses 14 are arranged on the outer periphery of the disk 15 on the circumference of a predetermined radius from the rotation center P1, and then the outer peripheral surface of the one or more protrusions 13 is formed. Is cut so as to be located on the circumference of a predetermined radius centered on the eccentric position P2. For this reason, the depth of the recessed part 14 is small in the part which cut | disconnected the outer peripheral surface of the convex part 13. FIG.

  Then, by arranging the disks 15 having such a configuration on the rotating shaft 16 in the axial direction, as shown in FIG. 1, the convex portions 13 arranged in the circumferential direction of both the rollers 11 and 12 are As described above, the distance from the rotation center P1 of the rollers 11 and 12 to the outer peripheral edge 13a of each convex portion 13, that is, the height is continuously changed.

  Unlike the above, as the disk 15 constituting one of the rollers 11 or 12, the outer peripheral edge of the convex portion 13 is located on a circle centering on the rotation center of the roller 11 or 12, that is, all convex The part 13 having the same height from the rotation center of the roller 11 or 12 may be used.

  Further, in this embodiment, as shown in FIG. 2, a plurality of types of disks 15 having different outer dimensions are used as the disks 15 of the rollers 11 and 12. In this case, the disks 15 are similar to each other, and the change pattern of the outer peripheral edge of the convex portion 13 is the same. The rollers 11 and 12 are arranged such that the disks 15 are successively different in diameter along the axial direction so that the outer shape changes in order along the axial direction. Thereby, also in the convex part 13 arranged in the axial direction linear form of both the rollers 11 and 12, the distance from the rotation center P1 of the rollers 11 and 12 to the outer peripheral edge 13a of each convex part 13, that is, the height of the convex part 13 Changes continuously, and the phase of the change coincides in the axial direction of the rollers 11 and 12. Therefore, at the rotation angle position where the high convex portion 13 is positioned on one disk 15, the high convex portion 13 is similarly positioned in the other disks 15 superposed in the axial direction.

  Therefore, the outer peripheral edge 13a of the convex portion 13 of both the rollers 11 and 12 is undulated in the axial direction of the rollers 11 and 12, as shown in FIG. Has occurred. In the circumferential direction of the rollers 11 and 12, the outer peripheral edge 13 a of the convex portion 13 draws an eccentric locus as apparent from FIG. 1 as the rollers 11 and 12 rotate.

  Further, as shown in FIG. 2, the upper roller 11 and the lower roller 12 are so that the outer shape change state is reversed, in other words, the height change pattern of the convex portion 13 is changed between the upper roller 11 and the lower roller 12. Then, it is comprised so that it may become an antiphase. As a result, as shown in FIG. 2, a substantially constant distance is maintained between the outer peripheral edge 13a of the convex portion 13 on the upper roller 11 and the outer peripheral edge 13a of the convex portion 13 on the lower roller 12. It has become.

  As a result, when the crushing process is applied to the cushion sheet 18, the height and depth of a large number of peak portions 18a and valley portions 18b change according to the height of the outer peripheral edge 13a of the convex portion 13, As shown in FIG. 5 to FIG. 7, the entire corrugated surface composed of a large number of crests 18 a and troughs 18 b has a desired undulation such as a curved shape along the feeding direction of the cushion sheet 18 and the direction perpendicular thereto. It is formed integrally with the base portion 18c so as to form a shape, and the top portion of the peak portion 18a is positioned on a desired undulating surface.

  As described above, when the disk 15 having the same height of all the convex portions 13 is used in one roller 11 or 12, the interval between the upper and lower convex portions 13 is accompanied by the rotation of the rollers 11 and 12. However, even in this case, if the height of the convex portion 13 of the other roller 11 or 12 is different, the height of the peak portion 18a and the valley portion 18b of the cushion sheet 18 is different, and the cushion sheet 18 as a whole is changed. A desired undulation shape can be obtained. However, the width of the space between the upper and lower convex portions 13 appears as a difference in height between the peak portion 18 a and the valley portion 18 b of the cushion sheet 18.

Next, a wave splitting method using the wave splitting apparatus configured as described above will be described.
Now, when the upper roller 11 and the lower roller 12 are synchronously rotated in the direction of the arrow in FIG. 1 by a motor (not shown), the cushion sheet 18 is inserted between the rollers 11 and 12, and the cushion sheet 18 is moved to the both rollers 11. , 12 are compressed in the direction of the arrow in FIG. At this time, the cushion sheet 18 before elastic restoration is cut and separated by the cutting blade 19 on the delivery side of the cushion sheet 18. Thus, in a state where the cushion sheet 18 is elastically restored by its own elasticity, a wave-shaped surface including a large number of peak portions 18a and valley portions 18b that are integrated with the base portion 18c is formed on the cut surface side.

  In this case, the convex portions 13 arranged in the circumferential direction and the axial direction of the rollers 11 and 12 continuously change the distance from the rotation center P1 of the rollers 11 and 12 to the outer peripheral edge 13a of each convex portion 13. The height is continuously different. For this reason, as shown in FIGS. 5 to 7, on the wave splitting surface formed by a large number of ridges 18 a and valleys 18 b formed on the cut surface of the cushion sheet 18, in other words, the top of the ridges 18 a and In the bottom of the valley portion 18b, undulations appear in the feeding direction of the cushion sheet 18 and in the width direction perpendicular thereto in accordance with the change in the height of the convex portion 13 on the rollers 11 and 12. That is, as is apparent from FIG. 2, in the cushion sheet 18, undulations representing the change pattern of the diameter of the disk 15 appear in the axial direction of the rollers 11 and 12. Further, in the circumferential direction of the rollers 11 and 12, undulations representing a change pattern of the height of the convex portion 13 appear, and this is repeated with one rotation of the rollers 11 and 12 as one cycle. Therefore, by appropriately setting the change pattern of the diameter of the disk 15 and the change pattern of the height of the convex portion 13, the cushion sheet 18 after the wave splitting process is used as a filler such as bedding, a sheet, and a pillow. In this case, the wave splitting surface can be fitted to the body by matching the curve of the user's body, and the comfort can be improved.

(Second Embodiment)
Next, a second embodiment of the present invention will be described with a focus on differences from the first embodiment.
In the second embodiment, as shown in FIG. 8, the rotary shaft 16 is configured to rotate around a position P4 that is eccentric from the center P3. Therefore, in both rollers 11 and 12, a plurality of convex portions 13 and concave portions 14 on the outer periphery of the disk 15 are arrayed on a predetermined circumference centered on the eccentric position P4. For this reason, unlike the case of the first embodiment, even if the depth of each concave portion 14 is uniform, the height of the convex portion 13 from the center of rotation of the rollers 11 and 12 by the rotation of the rotating shaft 16 is increased. It will change continuously.

Therefore, also in the second embodiment, the same effect as in the first embodiment can be obtained.
(Example of change)
In addition, this embodiment can also be changed and embodied as follows.

  In the above-described embodiment, the phase of the height change of the convex portion 13 is made coincident only by changing the diameter of the disk 15 in the axial direction of the rollers 11 and 12. Shift continuously in the direction. For example, the high convex portion 13 of each disk 15 is continuously displaced in the circumferential direction in the axial direction of the rollers 11 and 12. In this way, the undulation of the cushion sheet 18 changes in an oblique direction with respect to the axial direction of the rollers 11 and 12, and a complicated undulation shape can be obtained.

  In the embodiment, the outer peripheral edge 13a of the convex portion 13 of the disk 15 is arranged on one eccentric circle, but it is arranged on a plurality of eccentric circles. Therefore, in this case, the outer peripheral edge 13 a of the convex portion 13 enters and exits in the radial direction at a plurality of locations on the outer periphery of the disk 15.

  The protrusion 13 is formed integrally with the outer peripheral surface of the cylindrical roller in a juxtaposed state.

The principal part sectional view showing the wave cutting apparatus of a 1st embodiment. FIG. 2 is a schematic sectional view taken along line 2-2 of FIG. The principal part expansion perspective view which shows the roller of the wave splitting apparatus of FIG. The side view which expands and similarly shows the disk of a roller. The principal part perspective view which shows the sheet | seat material processed with the wave splitting apparatus of FIG. FIG. 6 is a main part sectional view taken along line 6-6 in FIG. 5; FIG. 7 is an essential part cross-sectional view taken along line 7-7 in FIG. 5; The side view which shows the disk of the roller of 2nd Embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Upper roller, 12 ... Lower roller, 13 ... Convex part, 13a ... Outer periphery, 14 ... Concave part, 15 ... Disc, 15a ... Outer fitting hole, 16 ... Rotating shaft, 18 ... Cushion sheet, 18a ... Mountain part, 18b ... Valley part, 18c ... Base part, 19 ... Cutting blades as cutting means, P1, P3 ... Center of rotation, P2, P4 ... Eccentric position.

Claims (4)

In the cushion sheet formed on one side surface of the base portion with the wave splitting surface composed of a plurality of peak portions and valley portions, the base portion and the peak portion are integrally formed, and a virtual surface along the top of each peak portion Is formed to form an undulating surface,
The cushion sheet which made the said virtual surface undulate in one direction and the direction orthogonal to it by changing the thickness of the said base part in one direction and the direction orthogonal to it by making the peak-valley difference of a peak part and a valley part constant . A pair of rollers formed by alternately arranging a plurality of convex portions and concave portions on the outer peripheral surface along the circumferential direction and the axial direction are arranged in parallel so that the concave and convex portions correspond to each other alternately. Rotating the roller, inserting the cushion sheet between both rollers and feeding it in one direction while compressing between both concave and convex parts, cutting the cushion sheet before elastic restoration between both rollers on the sending side of the cushion sheet In the wave splitting device which is cut and separated by the above, and the cutting surface side is subjected to wave splitting processing,
Among the plurality of protrusions provided on both rollers, the protrusions arranged on the same circumference are formed such that the height from the rotation center continuously changes in the circumferential direction,
Of the plurality of protrusions provided on the two rollers, the protrusions arranged on the same axial line are formed such that the height from the rotation center continuously changes in the axial direction.
The both rollers are a wave cutting apparatus in which the height change patterns from the rotation center of the convex portion in the circumferential direction and the axial direction are arranged in opposite phases . The both rollers are configured by superimposing a plurality of discs in which a plurality of convex portions and concave portions are alternately arranged in the circumferential direction on the outer peripheral surface in the axial direction ,
The plurality of disks attached to the same roller have a similar shape to each other, have different diameters based on the outer peripheral edge of the convex portion, and are arranged so that the diameter continuously changes along the axial direction. The wave splitting device according to claim 2 . A pair of rollers formed by alternately arranging a plurality of convex portions and concave portions on the outer peripheral surface along the circumferential direction and the axial direction, and arranged on the same circumference among the plurality of convex portions provided on the roller The raised protrusions are formed such that the height from the rotation center continuously changes in the circumferential direction, and is arranged on the same axial direction line among the plurality of raised parts provided on the roller. The convex portion is a pair of rollers formed so that the height from the rotation center continuously changes in the axial direction, and the concave and convex portions correspond to each other alternately, and the convex portions in the circumferential direction and the axial direction are Rotating these rollers while inserting them in parallel so that the height change patterns from the center of rotation are in opposite phases, inserting a cushion sheet between both rollers and compressing between both concave and convex portions Send it in one direction In between the two rollers of the sheet feed side, and cut and separated by the cutting means cushion sheet before elastic recovery, the wave-breaking machining method of applying a wave-breaking machining on the cut surface.

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