Patent Publication Number: US-2022225846-A1

Title: Manufacturing method and manufacturing equipment for corrugated net

Description:
BACKGROUND OF THE INVENTION 
     Field of Invention 
     The invention relates to a manufacturing method of mesh material for making bath accessories, and more particularly to a manufacturing method and a manufacturing equipment for a corrugated net. 
     Related Art 
     When a person bathes or takes a shower, and washes his or her body, in order to increase the foam produced by the shower cream and increase the effect of exfoliating, a bath accessory such as a bath ball made of a corrugated net is used.  FIG. 1  shows a conventional equipment  10  for making a corrugated net, firstly, a net  11  is guided to a heating module  12  formed by a heating plate for heating, and the net  11  is heated (up) to a moldable temperature, so that the net  11  features thermoplastic deformability due to heat, and then the net  11  is guided to a roller set  13 , and the said net, which is previously heated up into a state of being moldable, is then squeezed into a container  14 , because the net  11  is continuously guided into the container  14 , the net  11  in the moldable state is continuously pressed in the container  14  to produce corrugated deformation. After the net  11  in the container  14  accumulates a certain volume and pressure, the pressed net  11  will be released from the container  14  to complete the manufacture of the corrugated net. 
     However, during the manufacture of the aforementioned conventional corrugated net, the net  11  being used has been cooled and wound, because the net  11  has been cooled and cannot be directly thermoplastically deformed to produce creases, so the heating module  12  is disposed to heat the net  11  to a moldable temperature, and then the net  11  is moved to the container  14  of the equipment  10  to be pressed to form creases. Since the net  11  is an injection-molded mesh body, a thickness of each part is different, and because the heating module  12  conducts heat through air, when the heating module  12  heats the net  11 , poor heat conduction efficiency makes the heating effect on the net  11  uneven, and only outer sides of the net  11  and positions close to the heating module  12  will be heated, causing the heating effect on the inner and outer sides uneven. 
     In addition, when the heating module  12  is used for a long period of time, the cost of electricity consumption is also quite high, resulting in an increase in the overall manufacturing costs, or the heating effect being insufficient, and the net  11  being incapable of reaching a moldable state. Furthermore, the heating module  12  needs to heat the net  11  to a predetermined temperature, so a longer heating time or the heating module  12  with a longer length is required to heat the net  11  to a moldable temperature, thus limiting the feeding speed of the net  11 , being incapable of increasing the productivity, and relatively increasing the heating costs of the equipment and the defective rate of the corrugated net in the manufacturing process. Therefore, in the conventional corrugated net manufacturing process, in addition to the pre-operation of cooling and winding before the net  11  is processed, the wound net  11  also needs to be released for heating afterwards, which makes the time required for the whole manufacturing process of the corrugated net and the pre-operation relatively lengthy and increases unnecessary costs. 
     SUMMARY OF THE INVENTION 
     A main object of the invention is to provide a manufacturing method and a manufacturing equipment for directly forming a corrugated net in a same manufacturing process after injection molding to simplify the manufacturing process. 
     Another object of the invention is to provide a manufacturing method and a manufacturing equipment for a corrugated net, which do not require additional heating equipment to heat the net to be capable of reducing processing and equipment costs. 
     In order to achieve the above-mentioned objects, the invention provides a manufacturing method for a corrugated net, comprising: 
     A. an injection step: injecting a thermoplastic plastic mesh material, the plastic mesh material having an injection temperature; 
     B. holding temperature control: directly guiding the plastic mesh material with the injection temperature to a temperature adjustment equipment, and cooling the plastic mesh material down to a moldable temperature; and 
     C. corrugation by pressing: pressing the plastic mesh material with the moldable temperature to cause the plastic mesh material with the moldable temperature to form creases during the pressing process. 
     And, in order to achieve the above manufacturing method, the manufacturing equipment for the corrugated net provided by the invention comprises: 
     an injection machine with an injection mechanism capable of injecting a thermoplastic plastic mesh material with an injection temperature; 
     a temperature adjustment equipment with a holding temperature space, the holding temperature space is accommodated with a liquid holding temperature medium to cool the plastic mesh material down to a moldable temperature by the liquid holding temperature medium; and 
     a pressing unit with a compartment, inside the compartment is a chamber, the plastic mesh material is pressed in the chamber to form creases; the chamber is also provided with a compartment door, the compartment door opens and closes according to changes of a pressing pressure in the chamber to make the corrugated net. 
     The manufacturing method and the manufacturing equipment for the corrugated net provided by the invention are capable of firstly and directly reducing a temperature of the injected thermoplastic plastic mesh material from the injection temperature to the moldable temperature through the temperature adjustment equipment, and then pressing the plastic mesh material with the moldable temperature to form creases. Compared with the conventional manufacturing method employing a two-stage process of cooling and winding the plastic mesh material, and then heating the wound plastic mesh material, the manufacturing method of the invention does not require additional heat sources or heating equipment to heat the plastic mesh material, temperatures inside and outside the plastic mesh material can be made uniform, and uniform creases can be formed during pressing to improve a yield of the finished product, and the invention is a continuous one-time processing procedure from injection to pressing to form creases, which can reduce manufacturing time and costs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention can be best understood through the following description and accompanying drawings, wherein: 
         FIG. 1  is a schematic diagram of a conventional method and equipment for manufacturing a corrugated net; 
         FIG. 2  is a schematic diagram of an overall equipment according to a preferred embodiment of the invention; 
         FIG. 3  is a production flow chart according to a preferred embodiment of the invention; 
         FIG. 4  is a schematic diagram of a plastic mesh material injected by an injection machine according to a preferred embodiment of the invention; 
         FIG. 5  is a schematic diagram of a temperature of the plastic mesh material being directly cooled down by a temperature adjustment equipment after injection molding according to a preferred embodiment of the invention; 
         FIG. 6  is a schematic diagram of draining after the plastic mesh material is guided out of the temperature adjustment equipment according to a preferred embodiment of the invention; 
         FIG. 7  is a schematic diagram of the plastic mesh material being pressed in a pressing unit to form creases according to a preferred embodiment of the invention; 
         FIG. 8  is a schematic diagram of operations of the overall equipment according to a preferred embodiment of the invention; 
         FIG. 9  is a schematic diagram of the corrugated net made by the manufacturing method of the invention; 
         FIG. 10  is a perspective view of a bath ball made from the corrugated net of the invention; and 
         FIG. 11  is a perspective view of a bath glove made from the corrugated net of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Please refer to  FIGS. 2 to 3  for a manufacturing equipment and a manufacturing process for a corrugated net provided by a preferred embodiment of the invention. The equipment comprises following components: 
     An injection machine  20  as shown in  FIGS. 2 and 4 , the injection machine  20  has an injection mechanism  21 , the injection mechanism  21  is capable of continuously injecting thermoplastic raw materials to form a thermoplastic plastic mesh material  22  as required. The plastic mesh material  22  is a continuous mesh structure, but it is not limited thereto; as long as it is a plastic product with thermoplasticity, it can be made to form creases; when the plastic mesh material  22  is injected and formed by the injection mechanism  21 , the plastic mesh material  22  has an injection temperature, and the temperature is between 160 and 300 degrees Celsius. 
     A temperature adjustment equipment  30  as shown in  FIGS. 5 and 6 , in this embodiment, the temperature adjustment equipment  30  is composed of a solution tank  31 , a roller  32  and a temperature control device  34 . Inside the solution tank  31  is a holding temperature space, inside the holding temperature space can be filled with a liquid holding temperature medium  33  to keep the holding temperature space of the solution tank  31  at a certain temperature; the liquid holding temperature medium  33  in this embodiment is warm water between 40 and 80 degrees Celsius. The temperature control device  34  is provided with a temperature sensor  341  and a circulating solution tank  342 , the temperature sensor  341  senses a temperature of the liquid holding temperature medium  33  of the solution tank  31 ; the circulating solution tank  342  is an exchange tank with a liquid holding temperature medium (exchange medium for short) for exchange and with a lower temperature. In this embodiment, the circulating solution tank  342  is a cold water tank with a lower temperature, and its exchange medium is cold water with a lower temperature. The circulating solution tank  342  of the temperature control device  34  communicates with the solution tank  31  through an outlet  343  and an inlet  344  for circulating the liquid holding temperature medium  33 . When the temperature sensor  341  senses that a water temperature of the liquid holding temperature medium  33  in the solution tank  31  rises and changes, for example, when a temperature of the liquid holding temperature medium  33  is increased to a set temperature (for example, 70° C., but it is not limited thereto) caused by continuous importing of the plastic mesh material  22  into the solution tank  31 , exchange process of the holding temperature medium is started. The liquid holding temperature medium  33  is circulated and exchanged between the circulating solution tank  342  and the solution tank  31  through the outlet  343  and the inlet  344  in order to adjust a temperature of the liquid holding temperature medium  33  in the holding temperature space of the solution tank  31 , so that a liquid temperature in the solution tank  31  can be maintained within a fixed temperature range; and the roller  32  is disposed inside the solution tank  31 . Further comprising: a draining wheel set  36  disposed outside the solution tank  31 . 
     A pressing unit  40  as shown in  FIG. 7 , the pressing unit  40  has a guiding wheel set  41 , a compartment  42  and a counterweight  43 ; the guiding wheel set  41  is disposed in front of the compartment  42 , and the compartment  42  is provided with an importing port  421  adjacent to the guiding wheel set  41 . Inside the compartment  42  is provided with a chamber  422 , and the importing port  421  communicates with the chamber  422 . The compartment  42  is additionally provided with a compartment door  423 , the compartment door  423  is capable of selectively opening or closing the chamber  422 , so that the chamber  422  is in an opened or a closed state. The counterweight  43  is hung on an outer side of the compartment door  423 , and is capable of providing the compartment door  423  with a closing weight. When a pressure in the chamber  422  is greater than a closing force of the counterweight  43  and the compartment door  423 , the compartment door  423  will be pushed and opened, so that the chamber  422  is in an opened state, and the plastic mesh material  22  can be released from the chamber  422 . 
     A heat preservation unit  50  as shown in  FIG. 7 , the heat preservation unit  50  is provided between the temperature adjustment equipment  30  and the pressing unit  40 . In this embodiment, the heat preservation unit  50  is disposed at a position where the draining wheel set  36  and the guiding wheel set  41  are provided, inside the heat preservation unit  50  is a heat preservation chamber  51 , and a temperature in the heat preservation chamber  51  is kept within a moldable temperature range of the plastic mesh material  22 . The draining wheel set  36  and the guiding wheel set  41  are also located in a moldable temperature environment. 
     Please refer to  FIGS. 3 and 8 , a manufacturing method for the corrugated net of the invention comprises following steps of: 
     A. an injection step: referring to  FIG. 4 , injecting and forming the plastic mesh material  22  continuously through the injection mechanism  21  of the injection machine  20 , the plastic mesh material  22  being a tubular mesh material with meshes, the plastic mesh material  22  having the injection temperature and being in a high temperature state right after being injected; and then transferring the injection-molded plastic mesh material  22  directly to the temperature adjustment equipment  30 ; 
     B. holding temperature control: referring to  FIGS. 5 and 6 , transferring the plastic mesh material  22  with the injection temperature toward the temperature adjustment equipment  30 , transferring the plastic mesh material  22  into the solution tank  31 , winding the plastic mesh material  22  on the roller  32  so that inside and outside of the plastic mesh material  22  being fully immersed in the solution tank  31 ; because the solution tank  31  is filled with the liquid holding temperature medium  33  of 40 to 80 degrees Celsius, the original injection temperature of the plastic mesh material  22  is controlled and reduced to a temperature close to that of the liquid holding temperature medium  33  in the solution tank  31 , so that a temperature of the plastic mesh material  22  is maintained at a moldable and deformable operating temperature—that is, a moldable temperature of 40 to 80 degrees Celsius; because the plastic mesh material  22  originally has a relatively high temperature after being injection-molded by the injection machine  20 , when the plastic mesh material  22  is guided into the solution tank  31 , a temperature of the liquid holding temperature medium  33  in the holding temperature space of the solution tank  31  will also increase relatively, through the temperature control device  34 , the temperature sensor  341  can sense a temperature in the solution tank  31 , and the exchange medium is imported from the circulating solution tank  342  to adjust a temperature of the liquid holding temperature medium  33  and through circulation of the exchange medium to keep a temperature of the holding temperature space of the solution tank  31  within the moldable temperature range; in addition, a thermostat (not shown in the figures) can be circumferentially disposed on the solution tank  31 , and a temperature in the solution tank  31  can be controlled directly through the thermostat; in this embodiment, rollers are used to continuously transfer the plastic mesh material  22 , after a temperature of the plastic mesh material  22  is cooled down to the moldable temperature in the solution tank  31 , the plastic mesh material  22  is removed from the solution tank  31 , and then the plastic mesh material  22  is inserted into the draining wheel set  36 , the draining wheel set  36  will exert a pressing effect on the plastic mesh material  22  to drain the liquid holding temperature medium  33  impregnated in the plastic mesh material  22 , that is, squeezing out the water; it should be explained that it is not necessary for the draining wheel set  36  to completely drain the water absorbed by the plastic mesh material  22 , it is only required to drain most of the water; 
     B1. a heat preservation step: referring to  FIG. 7 , the heat preservation unit  50  forming a heat preservation effect on the plastic mesh material  22  removed from the temperature adjustment equipment  30  and preventing temperature reduction, for example, by disposing insulation material in the heat preservation chamber  51 ; the plastic mesh material  22  passes through the heat preservation chamber  51 , so that the plastic mesh material  22  is not directly exposed to the outside, and a temperature of the plastic mesh material  22  can be maintained within the moldable temperature range; and 
     C. corrugation by pressing: referring to  FIG. 7 , after the plastic mesh material  22  passing through the draining wheel set  36 , a temperature of the plastic mesh material  22  being equal to or slightly lower than a temperature in the solution tank  31 , but still maintained within the thermoplastic moldable temperature, then, the plastic mesh material  22  being guided into the pressing unit  40 , and the plastic mesh material  22  being inserted into the guiding wheel set  41 ; the heat preservation unit  50  is capable of ensuring that a temperature of the plastic mesh material  22  after it being removed from the temperature adjustment equipment  30  and before entering the pressing unit  40  can be maintained within the moldable temperature to avoid a sudden temperature drop; the guiding wheel set  41  will continue to tuck the plastic mesh material  22  from the importing port  421  of the compartment  42  into the chamber  422 ; the plastic mesh material  22  is pressed in the chamber  422  to form an irregular stack, because the plastic mesh material  22  is still maintained within the thermoplastic deformable moldable temperature, when the plastic mesh material  22  is pressed in the chamber  422  until generated creases of the plastic mesh material  22  in the chamber  422  accumulate to a certain extent, a pressing pressure generated by the plastic mesh material  22  will exert a pushing effect on the compartment door  423 , when a pushing force of the plastic mesh material  22  is greater than a weight of the counterweight  43 , the plastic mesh material  22  will push and open the compartment door  423 , so that the pressed plastic mesh material  22  will be released from an opened position of the compartment door  423  to form the corrugated net  25  as shown in  FIG. 9 . The corrugated net  25  of  FIG. 9  is an illustration only and is not limited thereto. 
     In the method and the equipment for manufacturing the corrugated net provided by the invention, after the injection machine injects the plastic mesh material with the injection temperature, a temperature of the plastic mesh material is directly reduced to the moldable temperature for processing to form creases; compared with the conventional manufacturing method of cooling and winding the plastic mesh material before heating, the manufacturing method of the invention does not require heating after cooling, which reduces processing procedures, and the plastic mesh material is completed in one processing procedure from injection to pressing to form creases. In addition to reducing the production time, further processing steps can be eliminated. Furthermore, the manufacturing method of the invention does not require heating equipment, which can save the costs of heating equipment and electricity. In addition, the manufacturing method of the invention cools the plastic mesh material down to the moldable temperature through the liquid holding temperature medium of the temperature adjustment equipment, the liquid heat exchange effect is good and the speed is fast, so that the plastic mesh material has the same moldable temperature inside and outside without temperature difference, and the creases formed by pressing are more uniform, which can improve the yield and quality. 
     Please refer to  FIG. 10  and  FIG. 11 , after the plastic mesh material  22  is creased and corrugated, and made into the corrugated net  25 , the corrugated net  25  can be manufactured into a variety of bath supplies catering to various requirements. For example, the corrugated net  25  can be made into a bath ball  60  or a bath glove  65 . Because of creases in the surface of the corrugated net  25 , through scrubbing and rubbing the said material with soap or body wash, an effect to produce foams and bubbles is enhanced, which increases an effect of cleaning. 
     It is to be understood that the above description is only preferred embodiments of the present invention and is not used to limit the present invention, and changes in accordance with the concepts of the present invention may be made without departing from the spirit of the present invention, for example, the equivalent effects produced by various transformations, variations, modifications and applications made to the configurations or arrangements shall still fall within the scope covered by the appended claims of the present invention.