JP7835456B2 - Apparatus for manufacturing a functional mat, a method for manufacturing a functional mat, and a method for manufacturing an insole including a functional mat. - Google Patents

Description

This invention relates to a manufacturing apparatus capable of producing functional mats with excellent moisture absorption and deodorizing properties, which are used as materials for building interiors and household goods.

The need for moisture absorption and deodorization is widespread, encompassing various situations such as building ventilation, preventing mold growth on bedding, and preventing foot dampness. In these applications, porous materials like activated carbon and silica gel are used, and to apply them in diverse forms such as walls and filters, a configuration involving sandwiching them between highly breathable sheet materials is employed. However, since porous materials cannot perform their functions of moisture absorption and deodorization without exposure to air, it was necessary to devise a way to appropriately expose the porous material to air between the sheet materials while simultaneously preventing it from spilling out.

Patent No. 3100336

The functional mat described in Patent Document 1 has a structure in which silica gel is scattered and sandwiched between two mat bodies, and the fibers of the nonwoven fabrics are intertwined by needle punching, thereby holding the silica gel inside. However, it is preferable that such a functional mat can be flexibly modified, such as by uniformly scattering the silica gel or by changing the amount of silica gel scattered as needed.

In view of the above-mentioned problems, the present invention aims to provide a manufacturing apparatus for a functional mat that can uniformly encapsulate a porous material, or, if necessary, change the content of the porous material with high precision, and a method for manufacturing the same.

The present invention, which solves the above problems, is a manufacturing apparatus for producing a functional mat in which a granular porous body is sandwiched between two or more sheet materials in an overlapping portion, comprising: a feeding device that moves the sheet materials in a predetermined direction and sandwiches the porous body; a dispensing device that scatters the porous body on one surface of the sheet materials; and an entanglement device that intertwines and connects the sheet materials sandwiching the porous body, wherein the dispensing device has an adjustment unit that can adjust the amount of the porous body that is scattered.
This configuration allows for the uniform encapsulation of porous materials in the manufacturing of functional mats, or enables precise adjustment of the silica gel content as needed.

In a preferred embodiment of the present invention, the spraying device has a hopper, and the adjustment unit is provided with a spraying amount adjustment member at the discharge port of the hopper.
This configuration allows for easy adjustment of the amount of porous material sprayed per unit time.

In a preferred embodiment of the present invention, the dispensing amount adjusting member is a rotating body that can rotate about one pivot axis, and has a retaining portion on its outer circumferential surface that can hold the granules of the porous material.
This configuration allows for easy adjustment of the amount of porous material to be sprayed while limiting its particle size.

In a preferred embodiment of the present invention, the adjustment unit is further provided with a position-adjustable measuring member in the gap between the discharge port and the spray volume adjustment member.
This configuration allows for more uniform distribution of the porous material.

In a preferred embodiment of the present invention, the invention further comprises a heating section capable of heat-treating the functional mat.
This configuration allows for easy modification of the properties of the functional mat.

The present invention, which solves the above problems, is a manufacturing method for producing a functional mat in which a granular porous body is sandwiched between two or more sheet materials in an overlapping portion, comprising: a spraying step of spraying the porous body onto one surface of the sheet materials; a feeding step of moving the sheet materials in a predetermined direction and sandwiching the porous body between them; and an entanglement step of intertwining and connecting the sheet materials that sandwich the porous body, wherein the spraying step further includes a spraying amount adjustment step in which the amount of the porous body sprayed can be adjusted by a spraying device having an adjustment unit.
This manufacturing method allows for the uniform encapsulation of porous materials in the production of functional mats, or enables precise adjustment of the silica gel content as needed.

The present invention, which solves the above problems, is a manufacturing method for producing an insole including a functional mat in which a granular porous material is sandwiched between two or more sheet materials, comprising: a scattering step of scattering the porous material onto one surface of the sheet materials; a feeding step of moving the sheet materials in a predetermined direction and sandwiching the porous material between them; an entanglement step of intertwining and connecting the sheet materials that sandwich the porous material between them; a cutting step of cutting the functional mat into a predetermined shape; and a sewing step of sewing the peripheral edges of the cut functional mat together, wherein the scattering step further includes a scattering amount adjustment step in which the amount of the porous material scattered can be adjusted by a scattering device having an adjustment unit.
This manufacturing method makes it possible to produce insoles in which porous materials can be uniformly encapsulated, or in which the silica gel content can be changed with high precision as needed.

To solve the above problems, the present invention provides a manufacturing apparatus for a functional mat that can uniformly encapsulate a porous material, or change the content of the porous material with high precision as needed, and a method for manufacturing the same.

This is a schematic diagram showing the configuration of a functional mat according to the first embodiment of the present invention. This is a schematic diagram showing the configuration of a manufacturing apparatus for functional mats according to the first embodiment of the present invention. This is a schematic diagram showing the configuration of a dispensing device in a manufacturing apparatus for functional mats according to the first embodiment of the present invention. This is a schematic diagram showing the configuration of a functional mat and a manufacturing apparatus therefor according to a second embodiment of the present invention. This is a schematic diagram showing the configuration of a manufacturing apparatus for functional mats according to a third embodiment of the present invention. This is a schematic diagram showing the configuration of a functional mat according to a third embodiment of the present invention.

The functional mat X and manufacturing apparatus Z according to each embodiment of the present invention will be described below with reference to the drawings. The description will detail the configuration of the embodiment, the method of implementation, and other embodiments in that order.
The embodiments described below are merely examples of the present invention, and the present invention is not limited to these embodiments.

≪First Embodiment≫
As shown in Figures 1(a) and 1(b), the functional mat X according to this embodiment has a structure in which a granular porous body 2 is sandwiched between the overlapping portions (superimposed portions; the same applies hereinafter) of at least two (two or more) sheet materials 1. As a result, the porous body 2 absorbs moisture and deodorizes inside the functional mat X.

The sheet material 1 is a breathable and easily deformable component, preferably a collection of fibers such as nonwoven fabric, cotton, or spunlace. This configuration allows for space to be introduced into the sandwiched porous body 2, fully utilizing the moisture-absorbing and deodorizing properties of the porous body 2.

The porous body 2 is a granular material with numerous irregularities on its surface. By trapping and retaining gases, moisture, etc., in the depressions, it enables moisture absorption and deodorization of the surrounding environment. The material of the porous body 2 is not particularly limited as long as it possesses hygroscopic and deodorizing properties. However, in this embodiment, from the viewpoint of having granular particles with a certain particle size, silica gel or pumice is preferred.

As shown in Figure 1(b), cross-linked fibers 11 extend from the sheet material 1 into the layer in which the porous body 2 is sandwiched between the sheet material 1. These cross-linked fibers 11 are drawn from fibers contained in the sheet material 1 and, by becoming entangled with the sheet material 1 on the opposite side of the porous body 2 layer, cross-link the two sheet materials 1, thereby holding the shape of the functional mat X and the porous body 2 without any means of holding it in place, such as adhesives. This configuration ensures gaps around the granules of the porous body 2, maintaining the shape of the functional mat X and allowing the hygroscopic and deodorizing properties of the porous body 2 to be utilized.

Figure 1(c) shows an insole Y, which is made by cutting a functional mat X to the shape of a shoe sole. Insole Y is made by cutting the functional mat X shown in Figures 1(a) and 1(b) into a predetermined shape (such as the shape of the shoe sole or the shape of the foot), and then sewing two sheets of material 1 together at the edges to form a bag. This configuration ensures high moisture absorption and deodorizing properties inside the shoe, improving comfort.

The insole Y may be a cup-shaped insole, where a thermosetting resin layer is added to one side of the functional mat X's sheet material 1, and the periphery of the other side of the sheet material 1 is raised. This configuration allows the insole Y to make more stable contact with the user's foot, improving comfort. Furthermore, the insole Y may have additional layers such as a shock-absorbing layer (mesh fabric, etc.), a layer to improve strength (knit fabric, etc.), an anti-slip layer (rubber sheet, etc.), or a heat-retaining layer (boa fabric, etc.).

As shown in Figure 2(a), the manufacturing apparatus Z is capable of producing the aforementioned functional mat X and comprises a feeding device 3, a dispensing device 4, and an entanglement device 5. The dispensing device 4 also has an adjustment unit P that can adjust the amount of porous material 2 dispensed per unit time (hereinafter simply referred to as "dispensing amount"). This allows the amount of porous material 2 contained in the functional mat X to be adjusted as needed.

The feeding device 3 feeds the strip-shaped sheet material 1 in its longitudinal direction at a predetermined speed, forming the production line of the manufacturing device Z. The feeding device 3 also includes, in order from upstream, a dispensing roller 31, a clamping roller 32, and a winding roller 33, and may further include a turning roller 34 as needed.

The feed roller 31 is a columnar or tubular member located at the upstream end of the feed-out process for the sheet material 1. It has a pivot axis in a horizontal direction and perpendicular to the direction in which the sheet material 1 is fed (hereinafter referred to as the width direction). This causes the feed roller 31 to rotate, pulling out the sheet material 1 wound around its side (around the pivot axis) and sending it to the downstream process.

The clamping rollers 32 are a pair of rollers that sandwich the porous material 2 scattered between two or more sheet materials 1 sent from the feed rollers 31. Each of the rollers constituting the clamping rollers 32 has a pivot axis in the width direction and is a cylindrical or tubular member. Furthermore, it is preferable that the gap between the pair of clamping rollers 32 be adjustable as needed. This configuration allows the thickness of the functional mat X to be changed according to the thickness of the sheet materials 1 and the amount of porous material 2.

The winding roller 33 is a columnar or tubular member located at the downstream end of the manufacturing apparatus Z, and has a pivot axis in the width direction. This causes the winding roller 33 to rotate, and the functional mat X is wound around its side (around the pivot axis) and collected.

The direction-changing roller 34 is a roller used to change and adjust the direction in which the sheet material 1 or functional mat X is fed, and is a cylindrical or tubular member having a pivot axis in the width direction. In this embodiment, by appropriately providing the direction-changing roller 34, it is possible to secure space for other devices between the paths for feeding the two sheets of sheet material 1, or to keep the overall size of the manufacturing apparatus Z down.
For example, in Figure 2(a), a directional roller 34 is provided on the path for the upper sheet material 1 in order to secure space for a spreading device 4 between the paths for sending the two sheet materials 1.

The dispensing device 4 is a device capable of dispensing the porous material 2 onto the surface of the sheet material 1, which is fed by the feeding device 3. It comprises a hopper 41, a dispensing amount adjustment member 42, and a basis marking member 43. Furthermore, the aforementioned adjustment unit P is a collective name for the dispensing amount adjustment member 42 and the basis marking member 43.

The hopper 41 is a tank capable of storing and discharging a fixed amount of granular material, and has a storage section 411 and a discharge port 412. Preferably, the width of the hopper 41 is approximately the same as the width of the sheet material 1 or each roller in the direction in which the sheet material 1 is fed. With this configuration, granules of the porous material 2 can be distributed from a single dispensing device 4.

The storage section 411 is a tank capable of storing a predetermined amount of granular material, and is a box-shaped member having the same width as the hopper 41. The discharge port 412 is a hole provided at the bottom of the storage section 411, and discharges the material stored in the storage section 411, such as granules of the porous body 2, downward.
The discharge port 412 has approximately the same width as the storage section 411, and its length in the direction in which the sheet material 1 is fed is determined in correspondence with the adjustment section P, which will be described later.
Furthermore, it is preferable that the bottom surface of the storage section 411 is sloped downwards toward the discharge port 412. With this configuration, the material inside the storage section 411 flows more reliably toward the discharge port 412, and uneven dispensing can be suppressed.

The spray volume adjustment member 42 is a cylindrical or tubular member provided to block a portion of the discharge port 412, and is a rotating body having a pivot axis in one direction. In this embodiment, as shown in Figure 3(a), it has a pivot axis in the width direction, and the central axis of the cylindrical or tubular member and the pivot axis are the same, and it rotates to sweep the discharge port 412.

The dispensing amount adjustment member 42 has numerous holding portions 421 on its outer circumferential surface. The holding portions 421 are recesses or holes provided on the outer circumferential surface of the dispensing amount adjustment member 42 that face inward when rotated, and they hold the granules of the porous material 2. As shown in Figure 3(c), the granules of the porous material 2 are held in the holding portions 421 and are removed from the hopper 41 as the dispensing amount adjustment member 42 rotates. Then, when the openings of the holding portions 421 rotate downwards, the porous material 2 falls from the holding portions 421 and is dispersed onto the sheet material 1.

The gap between the dispensing amount adjustment member 42 and the discharge port 412 of the hopper 41 is preferably approximately equal to the diameter of the granules of the porous material 2, or slightly larger, at the portion of the holding part 421. With this configuration, only the granules of the porous material 2 that enter the holding part 421 are dispensed onto the sheet material 1, allowing for easy adjustment of the dispensing amount by the angular velocity of the rotation of the dispensing amount adjustment member 42.

The measuring member 43 is a member provided near the gap between the spraying amount adjustment member 42 and the discharge port 412, and adjusts the amount of porous material 2 sprayed. As shown in Figure 3(c), the measuring member 43 translates in a direction that expands or contracts the gap between the spraying amount adjustment member 42 and the discharge port 412, and adjusts the amount of porous material granules 2 discharged from the gap at one time. With this configuration, the spraying amount can be easily adjusted even when the gap is wider than the particle size of the porous material granules 2, or when a spraying amount exceeding the adjustment range of the angular velocity of the spraying amount adjustment member 42 is required.
The shape of the base material member 43 is not particularly limited as long as it allows for adjustment of the amount of porous material 2 sprayed, or changes in the gap between the discharge port 412 and the spraying amount adjustment member 42. However, a shape that corresponds to the actual handling and the shape of the discharge port 412 is preferred, and examples include a flat plate shape, columnar shape, wedge shape, etc.

The entanglement device 5 comprises a drive device 51 and a needle 52, and is a device for entangling and connecting multiple sheet materials 1 that hold granules of the porous body 2. Needle punching is used to connect the sheet materials 1, and the drive device 51 oscillates the needle 52 up and down to the extent that the needle 52 penetrates all of the sheet materials 1.

As shown in Figure 2(b), the needle 52 has a needle body portion 521 and a protruding portion 522 that extends from the side of the needle body portion 521. By penetrating and retracting the sheet material 1, it loosens and extracts the fibers contained in the sheet material 1. This causes the fibers of multiple sheet materials 1 to crosslink with each other across the layer of porous material 2, connecting the sheet materials 1. Furthermore, the crosslinking fibers 11 that connect the sheet materials 1 surround the granules of the porous material 2, allowing them to be held between the sheet materials 1.

In Figures 2(a) and 2(b), only one needle 52 is shown for illustrative purposes; however, it is preferable to have multiple needles 52 in a single entanglement device 5. More preferably, a predetermined number of needles (e.g., m rows and n columns) are provided in the feed direction and width direction, according to the width and feed speed of the sheet material 1. This configuration allows for efficient and strong connection of the sheet materials 1, while also stably holding the granules of the porous body 2.

In the system for operating the manufacturing apparatus Z of this embodiment, the operating state of the feeding device 3 (which may be either the angular velocity of rotation of any of the rollers or the speed at which the sheet material 1 is fed) and the operating state (angular velocity) of the spreading amount adjustment member 42 may be individually controllable, or they may be linked and dependent on one or the other. Preferably, both can be switched. This configuration allows for easy adjustment of the amount of porous material 2 contained in the functional mat X.

The manufacturing apparatus Z may have the following configuration. However, the configuration shown below is merely an example, and its presence or absence can be determined arbitrarily unless otherwise specified.

<Example of changes>
The feed roller 31 may be a mounting part (such as a bearing or a support base supported by rollers) on which a columnar member having a pivot axis in the width direction can be rotatably installed, instead of the configuration shown in Figure 2(a). In this case, the sheet material 1 wound around the pivot axis is supported by the feed roller 31, and the sheet material 1 is fed by rotating the winding roller 33 to pull it out in the direction of the winding roller 33. With this configuration, the process of installing the sheet material 1 in the manufacturing apparatus Z can be simplified, and the work related to the manufacturing of the functional mat X can be made more efficient.

The clamping rollers 32 may be configured to allow for adjustment of the distance between the pair of rollers. For example, the upper roller may be configured to move up and down in the vertical direction. This configuration allows the functional mat X passing between the two rollers to be adjusted to a desired thickness.

As shown in Figures 2 and 3, the dispensing device 4 may have a slope 44. The slope 44 is a flat plate-shaped member extending from near the outer surface of the dispensing amount adjustment member 42 to near the height of the sheet material 1 to which the porous material 2 is dispensed. It is sloped downwards towards the sheet material 1, and the granules of the porous material 2 slide down along it. This reduces the length of free fall of the porous material 2 from the holding part 421 to the sheet material 1, thereby reducing variations in the landing point of the sheet material 1 and allowing for more uniform dispensing of the porous material 2 onto the sheet material 1.

The following details the methods for carrying out the present invention, using the drawings. The methods described below are examples only; the methods are not limited to these, and the order of the steps may vary.

≪Implementation Method≫
The user first attaches the sheet material 1 to the feeding device 3. At this time, the sheet material 1 is wrapped around the feed roller 31, passed between the clamping rollers 32, and then the leading edge of the sheet material 1 is wound up by the winding roller 33. Furthermore, by attaching auxiliary cloths with a length from the feed roller 31 to the winding roller 33 to both ends in the direction in which the sheet material 1 is fed, the porous material 2 can be automatically sprayed over the entire sheet material 1, thereby improving production efficiency.

Next, the user places the granular porous material 2 into the hopper 41 and determines the angular velocity of the dispensing amount adjustment member 42 and the position of the basis marking member 43 (dispensing amount adjustment step). Then, the feeding device 3 is operated to move the sheet material 1 towards the winding roller 33 (feeding step), and the dispensing amount adjustment member 42 is rotated accordingly to dispensing the porous material 2 onto the surface of the sheet material 1 (dispensing step). At this time, the operating states of the feeding device 3 and the dispensing amount adjustment member 42 may be controlled individually, or they may be linked and dependent on one or the other.

After multiple sheet materials 1 have gripped the granules of the porous body 2, or in conjunction with the start of operation of the feeding device 3, the user operates the entanglement device 5 to entangle and connect the fibers of the multiple sheet materials 1 (entanglement process). This generates cross-linked fibers 11, and the granules of the porous body 2 are held between the layers of the sheet materials 1.

The user then removes the functional mat X wound onto the winding roller 33, cuts the functional mat X into a strip or any other shape, or cuts it out using a die (cutting process), and sews its edges together to connect the sheet materials 1 (suturing process). This prevents the granules of the porous material 2 sealed inside the functional mat X from leaking out. First, the strip-shaped functional mat X can be applied to bedding (futons, mattresses, etc.) and other items that require a certain size. In addition, the cut shapes can be, for example, circular or shoe sole shapes. The former can be applied to filters for piping and ventilation devices, and the latter to the insole Y shown in Figure 1(c).
In particular, when layering or attaching another fabric to the functional mat X, it is preferable to attach all the fabrics before the cutting process.

Functional Mat X can be used as a moisture absorber and deodorizer in factories, logistics facilities (warehouses, containers, etc.), homes (closets, shoe cabinets, entrances, toilets, etc.), nursing care facilities, medical facilities, etc., in addition to the above. However, these are merely examples, and Functional Mat X may be used in other environments as well.

The functional mat X and manufacturing apparatus Z according to the second embodiment of the present invention will be described below with reference to the drawings. Note that components similar to those in the first embodiment will be described using the same reference numerals, and their explanation will be omitted.

≪Second Embodiment≫
As shown in Figure 4(a), the feeding device 3 has three feeding rollers 31. This differs from the first embodiment in that another sheet material 1 is added to the underside of the sheet material 1 on which the porous material granules 2 are scattered, and as shown in Figure 4(b), a functional mat X is manufactured in which two layers of sheet material 1 are provided on only one side.

As shown in Figure 4(b), the functional mat X consists of two sheet materials 1 sandwiching a porous body 2, with another sheet material 1 laminated on one side. This third sheet material 1 has a pattern printed on it, allowing for a patterned functional mat X.

As shown in Figure 4(a), the clamping roller 32 clamps the granules of the porous material 2 between the layers of two sheet materials 1, while simultaneously laminating a third sheet material 1. This allows for the lamination of three or more sheet materials 1 while minimizing the number of parts. Furthermore, by using a manufacturing apparatus Z and method that laminates sheet materials 1 with pre-printed patterns, the process becomes easier and more efficient compared to printing patterns on a finished functional mat X, as it allows printing on a thin and simple object.

The entanglement device 5 swings the needle 52 up and down to penetrate the three sheet materials 1 at once, entangling and connecting the fibers of each sheet material 1 through needle punching. This ensures a stable connection between the sheet materials 1.

The following describes a functional mat X and manufacturing apparatus Z according to a third embodiment of the present invention, using the drawings. Note that components similar to those in the first and second embodiments are described using the same reference numerals, and their explanation is omitted.

≪Third Embodiment≫
As shown in Figures 5(a) and 5(b), the manufacturing apparatus Z includes a heating unit 6 downstream of the entanglement device 5 that is capable of heat-treating the functional mat X. The heating unit 6 is a device capable of heating the sheet material 1 to a predetermined temperature range. With this configuration, the sheet material 1 can be heat-treated to impart appropriate properties (such as strength) to the functional mat X.

In the embodiment shown in Figure 5(a), the heating unit 6 is a heating roller 61. The heating roller 61 is a pair of rollers that grip the functional mat X, which is fed by the feeding device 3, in the same manner as the clamping roller 32. Each roller is a cylindrical or tubular member having a pivot axis in the width direction of the sheet material 1. Furthermore, it is possible to heat the surface portion that can come into contact with the sheet material 1 through rotation, and the heat from this surface portion is conducted to the sheet material 1, thereby heating the sheet material 1.

Furthermore, the heating roller 61 may be configured to allow for adjustment of the distance between the pair of rollers. This configuration allows for vertical movement of the upper roller, similar to the modification example of the clamping roller 32 described above. This configuration allows the functional mat X passing between the two rollers to be adjusted to the desired thickness in conjunction with the heat treatment.

In the embodiment shown in Figure 5(b), the heating unit 6 is a housing-type heating device 62. The housing-type heating device 62 has a path through which the functional mat X, fed by the feeding device 3, passes, and heating means (electric heating wires, hot air heaters, etc.) above and below this path (at least on one side), enabling the heating of the functional mat X by heat transfer or radiation.

The functional mat X, which undergoes heat treatment through the heating section 6, preferably has a form in which the sheet material 1 contains low-melting-point fibers 12. As shown in Figure 6(b), the low-melting-point fibers 12 are fibrous components blended into the fibers of the sheet material 1 and possessing a lower melting point compared to other fibers. Examples include low-melting-point cotton and thermoplastic resins.

In the functional mat X shown in Figure 6(b), the left figure shows the state before passing through the heating section 6 (i.e., before heat treatment), and the right figure shows the state after passing through the heating section 6 (after heat treatment). Before heat treatment, the functional mat X contains low-melting-point fibers 12 internally, and these low-melting-point fibers 12 are intertwined with other fibers of the sheet material 1. When this functional mat X is appropriately heated, only the low-melting-point fibers 12 melt. Then, when the functional mat X is cooled, the melted low-melting-point fibers 12 fix some of the fibers of the sheet material 1, improving its strength. This improves the strength of the manufactured functional mat X.

The heating unit 6 preferably has a thermometer capable of measuring its own temperature or the surface temperature of the functional mat X. This allows for heating while maintaining a temperature range that does not damage the sheet material 1, and makes it easier to maintain a temperature range where only the low-melting-point fibers 12 melt. Furthermore, it is more preferable that the heating unit 6 has a system that automatically controls the intensity of heating by the heating unit 6 by feeding back the temperature data acquired by the thermometer.

In this embodiment, the heating unit 6 is shown as being integrated with other components of the manufacturing apparatus Z in Figures 5(a) and 5(b). However, the heating unit 6 may also be configured as a separate, independent unit. This allows for the separation of the process of sandwiching the porous body 2 between the sheet material 1 and the process of heat-treating the functional mat X, thereby increasing the flexibility of the manufacturing process.

The following details the methods for carrying out the present invention, using the drawings. The methods described below are examples only; the methods are not limited to these, and the order of the steps may vary.

≪Implementation Method≫
After the sheet material 1 is connected by the entanglement device 5, or in conjunction with the start of operation of the feed device 3, the user operates the heating unit 6 to heat-treat the functional mat X, particularly the sheet material 1. At this time, the user adjusts the temperature of the heating unit 6 so that it is within an appropriate temperature range in which only the low-melting-point fibers 12 melt. As a result, only the low-melting-point fibers 12 melt inside the sheet material 1, connecting the surrounding fibers, and solidifying after passing through the heating unit 6, thereby improving the strength of the sheet material 1.

X Functional mat Y Insole Z Manufacturing equipment 1 Sheet material 11 Cross-linked fiber 12 Low melting point fiber 2 Porous body 3 Feeding device 31 Feeding roller 32 Clamping roller 33 Winding roller 34 Directional roller 4 Spreading device 41 Hopper 411 Storage section 412 Discharge port 42 Spreading amount adjustment member 421 Holding section 43 Basis member 44 Slope 5 Entangling device 51 Drive device 52 Needle 521 Needle body section 522 Protruding section 6 Heating section 61 Heating roller 62 Housing-type heating device P Adjustment section

Claims (6)

A manufacturing apparatus for producing a functional mat in which a granular porous material is sandwiched between two or more sheet materials containing low-melting-point fibers ,
The device comprises a feeding device that moves the sheet material in a predetermined direction and sandwiches the porous body between the sheet material, a dispensing device that scatters the porous body on one surface of the sheet material, an entanglement device that intertwines and connects the sheet materials that sandwich the porous body, and a heating unit capable of heat-treating the functional mat.
The feeding device has clamping rollers that sandwich the porous body between the sheet materials,
The spraying device has an adjustment unit that can adjust the amount of the porous material sprayed,
The entanglement device is provided downstream of the clamping roller and upstream of the heating section.
The aforementioned heating unit is a housing-type heating device, which is part of the manufacturing apparatus. The aforementioned spraying device has a hopper,
The adjustment unit is provided with a dispensing amount adjustment member at the discharge port of the hopper.
The manufacturing apparatus according to claim 1. The aforementioned spray amount adjustment member is a rotating body that can rotate about one pivot axis, and on its outer surface,
The porous material is provided with a retaining portion capable of holding the granules.
The manufacturing apparatus according to claim 2. The adjustment unit is further provided with a position-adjustable measuring member in the gap between the discharge port and the spray volume adjustment member.
The manufacturing apparatus according to claim 2. A method for producing a functional mat comprising sandwiching a granular porous material between two or more sheet materials containing low-melting-point fibers ,
A spraying step of spraying the porous material onto one surface of the sheet material,
A feeding step in which the sheet material is moved in a predetermined direction and the porous body is clamped by a clamping roller ,
An entanglement step in which the sheet materials sandwiching the porous body are intertwined and connected,
The heating step includes heating the functional mat using a housing-type heating device,
The entanglement process is performed after the porous body is sandwiched between the sheet material and before the heat treatment.
A manufacturing method wherein the spraying step further includes a spraying amount adjustment step that allows the amount of porous body sprayed to be adjusted by a spraying device having an adjustment unit. A method for manufacturing an insole including a functional mat in which a granular porous material is sandwiched between two or more sheet materials containing low-melting-point fibers ,
A spraying step of spraying the porous material onto one surface of the sheet material,
A feeding step in which the sheet material is moved in a predetermined direction and the porous body is clamped by a clamping roller ,
An entanglement step in which the sheet materials sandwiching the porous body are intertwined and connected,
A heating step in which the functional mat is heat-treated by a housing-type heating device,
A cutting process for cutting the functional mat into a predetermined shape,
The process includes a suturing step of suturing the peripheral edge of the cut-out functional mat,
The entanglement process is performed after the porous body is sandwiched between the sheet material and before the heat treatment.
A manufacturing method wherein the spraying step further includes a spraying amount adjustment step that allows the amount of porous body sprayed to be adjusted by a spraying device having an adjustment unit.