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Patent · US9561612B2 · B2 · US

Method for manufacturing three-dimensional netted structure

(11) Publication number
US9561612B2
(21) Application number
14/852,646
(22) Filing date
2015-09-14
(30) Priority date
2000-03-15
(43) Publication date
2017-02-07
(45) Date of grant
2017-02-07
(52) CPC
  • B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 48/05, 2043/3416, 2043/3433, 2043/463, 2043/464, 43/22, 47/0014, 47/0033, 47/0038, 47/004, 47/02, 47/084, 47/12, 47/126, 47/30, 47/34, 47/8815, 47/8895, 48/001, 48/0011, 48/0255, 48/07, 48/08, 48/11, 48/12, 48/13, 48/15, 48/303, 48/345, 48/355, 48/911, 48/919
  • B29D Producing particular articles from plastics or from substances in a plastic state: 28/00, 28/005
  • B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2023/06, 2023/12, 2025/00, 2027/06, 2067/00, 2077/00, 2101/12, 2105/06, 2105/0854, 2105/10, 2105/26
  • B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2028/00, 2031/3041, 2031/731
  • D04H Making textile fabrics, e.g. from fibres or filamentary material; fabrics made by such processes or apparatus, e.g. felts, non-woven fabrics; cotton-wool; wadding {; non-woven fabrics from staple fibres, filaments or yarns, bonded with at least one web-like material during their consolidation}: 3/011, 3/033, 3/037, 3/10
(73) Assignee
C-ENG CO LTD
(54) Title
Method for manufacturing three-dimensional netted structure
(57) Abstract

A three-dimensional netted structure having an upper surface, a lower surface, two side surfaces a left end surface, and a right end surface, including at least a plurality of filaments helically and randomly entangled and thermally bonded together, wherein the filaments are formed out of a thermoplastic resin by extrusion molding followed by cooling with a liquid; and the netted structure is four-surface molded, the upper surface, the lower surface and the two side surfaces being molded. An apparatus and a method for manufacturing the three-dimensional netted structure.

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Claims (4)

  1. A method of manufacturing a three-dimensional netted structure, the method comprising: extruding molten filaments of a thermoplastic resin downward from a die via a mouthpiece of the die having a plurality of holes, whereby the filaments drop under the force of gravity in between chutes and a pair of drawing-down units, said drawing-down units being submerged or partly-submerged in a liquid, wherein a distance between upper parts of said chutes is wider than a width of an assembly of said extruded filaments, and a distance between lower parts of the chutes and a distance between said drawing-down units are smaller than the width of the assembly of said extruded filaments; flowing the filaments along a liquid layer formed on said chutes to form loops in the filaments, contacting adjacent filaments with each other, entangling the filaments with each other, and dropping the filaments in-between said drawing-down units; drawing down the assembly of extruded filaments at a speed lower than the filament dropping speed by said drawing-down units, wherein four surfaces of the assembly of said filaments are contacting said chutes and a pair of said drawing-down units before or after said drawing-down units are submerged; and cooling said resultant filaments with a liquid.
  2. A method of manufacturing a three-dimensional netted structure, the method comprising: a) extruding filaments of a thermoplastic resin downward from a die via a mouthpiece of the die, the mouthpiece having a plurality of holes, whereby the filaments drop in between drawing-down units under a force of gravity at a dropping speed and form an assembly of filaments, the drawing-down units being submerged or partly-submerged in a liquid, wherein a distance between the drawing-down units is smaller than a width of the assembly of filaments; b) drawing down the assembly of filaments at a speed lower than the dropping speed by the drawing-down units, and contacting and compressing four surfaces of the assembly of filaments by the drawing-down units, whereby the four surfaces are formed to be flat, and a density of regions of the assembly of filaments which extend a predetermined distance from the four surfaces into an inner portion of the assembly of filaments is higher than a density of the inner portion; and c) cooling the assembly of filaments in a liquid.
  3. The method of claim 2, wherein the mouthpiece further comprises a slit extending in a lengthwise direction of the mouthpiece whereby the three-dimensional netted structure further comprises a substantially non-void-carrying sheet which forms a wavy shape in a direction in which the thermoplastic resin is extruded.
  4. The method of claim 2, wherein after extruding the filaments of the thermoplastic resin downward from the die via the mouthpiece, the filaments flow along a liquid layer formed on a chute to form loops in the filaments, and the filaments contact one another and become entangled with one another.

Citations (7)

  • US7625629B2
  • US8563121B2
  • US8563123B2
  • US8568635B2
  • US8757996B2
  • US8828293B2
  • US9174404B2
Record as JSON 
{
  "publication_number": "US9561612B2",
  "country": "US",
  "kind": "B2",
  "title": "Method for manufacturing three-dimensional netted structure",
  "abstract": "A three-dimensional netted structure having an upper surface, a lower surface, two side surfaces a left end surface, and a right end surface, including at least a plurality of filaments helically and randomly entangled and thermally bonded together, wherein the filaments are formed out of a thermoplastic resin by extrusion molding followed by cooling with a liquid; and the netted structure is four-surface molded, the upper surface, the lower surface and the two side surfaces being molded. An apparatus and a method for manufacturing the three-dimensional netted structure.",
  "claims": [
    "1. A method of manufacturing a three-dimensional netted structure, the method comprising: extruding molten filaments of a thermoplastic resin downward from a die via a mouthpiece of the die having a plurality of holes, whereby the filaments drop under the force of gravity in between chutes and a pair of drawing-down units, said drawing-down units being submerged or partly-submerged in a liquid, wherein a distance between upper parts of said chutes is wider than a width of an assembly of said extruded filaments, and a distance between lower parts of the chutes and a distance between said drawing-down units are smaller than the width of the assembly of said extruded filaments; flowing the filaments along a liquid layer formed on said chutes to form loops in the filaments, contacting adjacent filaments with each other, entangling the filaments with each other, and dropping the filaments in-between said drawing-down units; drawing down the assembly of extruded filaments at a speed lower than the filament dropping speed by said drawing-down units, wherein four surfaces of the assembly of said filaments are contacting said chutes and a pair of said drawing-down units before or after said drawing-down units are submerged; and cooling said resultant filaments with a liquid.",
    "2. A method of manufacturing a three-dimensional netted structure, the method comprising: a) extruding filaments of a thermoplastic resin downward from a die via a mouthpiece of the die, the mouthpiece having a plurality of holes, whereby the filaments drop in between drawing-down units under a force of gravity at a dropping speed and form an assembly of filaments, the drawing-down units being submerged or partly-submerged in a liquid, wherein a distance between the drawing-down units is smaller than a width of the assembly of filaments; b) drawing down the assembly of filaments at a speed lower than the dropping speed by the drawing-down units, and contacting and compressing four surfaces of the assembly of filaments by the drawing-down units, whereby the four surfaces are formed to be flat, and a density of regions of the assembly of filaments which extend a predetermined distance from the four surfaces into an inner portion of the assembly of filaments is higher than a density of the inner portion; and c) cooling the assembly of filaments in a liquid.",
    "3. The method of claim 2, wherein the mouthpiece further comprises a slit extending in a lengthwise direction of the mouthpiece whereby the three-dimensional netted structure further comprises a substantially non-void-carrying sheet which forms a wavy shape in a direction in which the thermoplastic resin is extruded.",
    "4. The method of claim 2, wherein after extruding the filaments of the thermoplastic resin downward from the die via the mouthpiece, the filaments flow along a liquid layer formed on a chute to form loops in the filaments, and the filaments contact one another and become entangled with one another."
  ],
  "cpc": [
    "B29C 48/05",
    "B29C 2043/3416",
    "B29C 2043/3433",
    "B29C 2043/463",
    "B29C 2043/464",
    "B29C 43/22",
    "B29C 47/0014",
    "B29C 47/0033",
    "B29C 47/0038",
    "B29C 47/004",
    "B29C 47/02",
    "B29C 47/084",
    "B29C 47/12",
    "B29C 47/126",
    "B29C 47/30",
    "B29C 47/34",
    "B29C 47/8815",
    "B29C 47/8895",
    "B29C 48/001",
    "B29C 48/0011",
    "B29C 48/0255",
    "B29C 48/07",
    "B29C 48/08",
    "B29C 48/11",
    "B29C 48/12",
    "B29C 48/13",
    "B29C 48/15",
    "B29C 48/303",
    "B29C 48/345",
    "B29C 48/355",
    "B29C 48/911",
    "B29C 48/919",
    "B29D 28/00",
    "B29D 28/005",
    "B29K 2023/06",
    "B29K 2023/12",
    "B29K 2025/00",
    "B29K 2027/06",
    "B29K 2067/00",
    "B29K 2077/00",
    "B29K 2101/12",
    "B29K 2105/06",
    "B29K 2105/0854",
    "B29K 2105/10",
    "B29K 2105/26",
    "B29L 2028/00",
    "B29L 2031/3041",
    "B29L 2031/731",
    "D04H 3/011",
    "D04H 3/033",
    "D04H 3/037",
    "D04H 3/10"
  ],
  "assignees": [
    "C-ENG CO LTD"
  ],
  "filing_date": "2015-09-14",
  "publication_date": "2017-02-07",
  "grant_date": "2017-02-07",
  "priority_date": "2000-03-15",
  "application_number": "US-201514852646-A",
  "family_id": "50029314",
  "citations": [
    "US7625629B2",
    "US8563121B2",
    "US8563123B2",
    "US8568635B2",
    "US8757996B2",
    "US8828293B2",
    "US9174404B2"
  ]
}

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