Method for manufacturing card clothing

Abstract

By removing burrs of the pin of the card clothing used in the slicker brush, and by giving a rounded distal ends, the feeling of use and safety of the slicker brush are improved, and removal of hair after use is facilitated. The method includes: a first process of implanting a plurality of pins made of metal wire on a base clothing to produce a card clothing; and a second process of polishing each pin of the card clothing, using a polishing material having flexibility and elasticity, in which in the second process, polishing is performed by rubbing, while pressing the polishing material against each of the pins, thereby manufacturing a card clothing having a rounded distal ends with no burr.

Claims

1. A method for manufacturing card clothing, the method comprising: a first process of implanting a plurality of pins made of metal wire on a base clothing to produce a card clothing; and a second process of polishing each pin of the card clothing, using a polishing material having flexibility and elasticity, wherein the polishing material comprises a non-woven fabric provided with polishing material particles, wherein the second process includes a process of polishing by rubbing, while pressing the polishing material against each of the pins and wrapping the polishing material around the distal ends of each pin to round the tip, wherein the first process has a process of implanting each pin into the base clothing of a band-like body, and a process of manufacturing the card clothing, by bending the distal ends of each pin at the same angle and in the same direction so that an inner side has an obtuse angle, and the second process has a process of moving the card clothing straight at a constant speed, and a process of rotating the non-woven fabric roller around which the non-woven fabric is wound, along a direction from a bent portion of each pin to the distal ends, while making contact with each pin of the card clothing to perform polishing, wherein, in the second process, the peripheral speed of the non-woven fabric roller is 1×10.sup.4π to 3×10.sup.4π(mm/min), the time required for polishing is 20 to 60 (s), and a rotational distance of the non-woven fabric roller required for polishing is 1×10.sup.4π(mm) or more.

2. The method for manufacturing card clothing according to claim 1, wherein a nylon non-woven fabric is used as the polishing material.

3. The method for manufacturing card clothing according to claim 1, wherein the non-woven fabric is impregnated with polishing material particles to the inside.

4. The method for manufacturing card clothing according to claim 1, wherein, in the second process, a width of the non-woven fabric roller is wider than a width in a short direction of the base clothing of a band-like body.

5. The method for manufacturing card clothing according to claim 2, wherein the non-woven fabric is impregnated with polishing material particles to the inside.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1(a) is a top view, and FIG. 1(b) is a partially enlarged cross-sectional view of an A-A cross section of a base clothing according to an embodiment of the invention;

(2) FIG. 2(a) is a side view, and FIG. 2(b) is a front view of a pin inserted into a base clothing according to the embodiment of the invention;

(3) FIG. 3(a) is a perspective view, FIG. 3(b) is a top view and FIG. 3(c) is a bottom view of a card clothing according to the embodiment of the invention;

(4) FIG. 4 is a schematic view of a method for manufacturing a card clothing for removing burrs according to the embodiment of the invention;

(5) FIG. 5 is a partially enlarged view of the method for manufacturing the card clothing for removing burrs according to the embodiment of the invention; and

(6) FIG. 6(a) is a perspective view, FIG. 6(b) is a side view, and FIG. 6(c) is a rear view of a slicker brush according to the embodiment of the invention.

MODE(S) FOR CARRYING OUT THE INVENTION

(7) Hereinafter, embodiments of the invention will be described in detail with reference to FIGS. 1 to 6.

(8) In the present embodiment, the method for manufacturing the card clothing for removing burrs is divided into a first process and a second process. The first process is a pin implantation process which implants a pin 1 made of a metal wire cut and molded on a base clothing 2 by an automatic pin implantation device 5 to produce a card clothing 3. The second process is a process of polishing each pin 1 of the card clothing 3 manufactured by the first process.

(9) 21 First Process>

(10) In the first process, the base clothing 2, which is the raw material, in the form of a band having a width of about 120 mm and a length of several tens of meters, and a metal wire in which a diameter is 0.26 mm and a cross section is a perfect circle, are accommodated in the automatic pin implantation device 5. The metal wire is a material of the pin 1, and stainless steel, steel or the like is suitably used. As the base clothing 2, one in which a surface layer 2a using a sheet of rubber, felt, sponge or the like and a base layer 2b using a cotton fabric, linen or the like are bonded is preferably. Further, in the present embodiment, the pin implantation in a width direction of the base clothing 2 is referred to as a row, and the pin implantation in a length direction is referred to as a stage.

(11) First, a pin implantation hole 4 for implanting the pin 1 in the base clothing 2 is bored. As illustrated in FIG. 1(a), two pin implantation holes 4 are provided in parallel to a long side direction of the substantially rectangular base clothing 2 with an interval of the holes of 3 mm. Due to an installation angle of the base clothing 2 to the automatic pin implantation device 5, as illustrated in FIG. 1(b), each pin implantation hole 4 has an inclination of 15° with respect to a vertical line down to the pin implantation surface.

(12) Next, the metal wire is cut into a predetermined length, and molded into a substantially U-shape to manufacture the pin 1. Then, both distal ends of the pin 1 are inserted into the above-described two pin implantation holes 4.

(13) Next, as illustrated in FIG. 2(a), both distal ends of the pin 1 are bent at a position about 5 mm from the distal ends. The bending angle is set to 45°. In this state, a distance from the base clothing 2 to the distal end of the pin 1 is about 15 mm.

(14) Furthermore, while shifting the pin implantation position by 3 mm, the pin implantation is repeated 15 times in the row direction. Above process is repeated 4 times in the stage direction. When the pin implantation of four stages is repeated six times in the stage direction, FIG. 3 is obtained. FIG. 3(b) is a top view of the card clothing 3, but the top from the root of the pin 1 is omitted.

(15) The automatic pin implantation device 5 illustrated in FIG. 4 performs the first process as described above fully automatically. As illustrated in FIG. 3, assuming that the card clothing 3 having the number of pins 1 (15×24) is one set, the automatic pin implantation device 5 continues to automatically perform the pin implantation on the base clothing 2, while spacing several cm apart for each set.

(16) <Second Process>

(17) As illustrated in FIG. 4, the card clothing 3 in which the pin implantation has been completed by the automatic pin implantation device 5 is delivered in the full length direction of the base clothing 2 at a speed of 45 (mm/min) by mechanical transport means 6 such as a drive roller. This speed is determined by the pin implantation speed of the automatic pin implantation device 5. The distal ends of each pin 1 are directed in an opposite direction to the transport direction.

(18) Moreover, a non-woven fabric roller 7 in which a non-woven fabric 7b is wound around circumferential surface of cylindrical roller 7a as a polishing material having flexibility and elasticity is provided on the distal end side of the pin 1 of the card clothing 3 delivered after finishing the pin implantation, and polishing is performed by rotating the non-woven fabric roller 7 in the direction from the bent portions of each pin 1 to the distal end. A width of the non-woven fabric roller 7 is designed to be wider than a width in the short direction of the base clothing 2. The rotational speed and the installation position can be changed, and are changed to appropriate values in accordance with the standard of the pin 1, the delivery speed of the card clothing 3 and the like. Here, an example is given and demonstrated.

(19) In FIG. 4, the non-woven fabric 7b of the non-woven fabric roller 7 is provided at a position where it touches the distal end 1 to 2 mm of each pin 1, and rotates at a speed of a peripheral velocity 2×10.sup.4π (mm/min) in the direction from the bent portion of each pin 1 to the distal end. A diameter of the cylindrical roller 7a is 100 mm, and the thickness of the non-woven fabric 7b is about 10 mm. Therefore, the diameter of the non-woven fabric roller 7 becomes 120 mm.

(20) The non-woven fabric 7b is made of nylon and impregnated with polishing material particles to the inside.

(21) FIG. 5 is a partially enlarged view of the card clothing 3 and the non-woven fabric roller 7 while the card clothing 3 is being polished in the second process. The non-woven fabric roller 7 is virtually assumed to be a perfect circle having a diameter of 120 mm for convenience of illustrating the following calculation process.

(22) A moving distance of the card clothing 3 from the point at which the one pin 1 comes in contact with the non-woven fabric roller 7 and the polishing is started to the point at which the one pin 1 is separated from the non-woven fabric roller 7 and the polishing is completed is a line segment d in FIG. 5. When the distal ends of each pin 1 come to the middle point of this line segment d, it penetrates most deeply into the non-woven fabric 7b. Assuming that the depth is 2 mm, the length of the line segment d is 2×√{(60).sup.2−(58).sup.2}≈30.7 (mm) from the Pythagorean theorem. The time required to move this distance is 30.7 (mm)÷(45/60) (mm/s)≈40.9 (s). The rotation distance of the non-woven fabric roller 7 until polishing of one pin 1 is {40.9/60 (min)}×{2×10.sup.4π (mm/min)}˜1.36×10.sup.4π (mm).

(23) Parameters such as shapes, dimensions, distances and speeds of the respective constituent members illustrated in the above-described embodiment are merely examples, and are not particularly limited. Mass production of the card clothing of uniform quality can be automated, by changing the pin implantation position and the pin implantation speed of the first process, and the work position and polishing speed of the second process, depending on the material or depending on the required card clothing standard.

(24) FIG. 6 is a view illustrating a usage example of using the card clothing 3, on which the second process is completed, as the slicker brush 8. First, as illustrated in FIGS. 1 and 2, the card clothing 3 on which the second process is completed is cut into a substantially rectangular shape for each set. Further, the cut card clothing 3 is placed on a plastically processable thin plate-like holding member 8a to which a handle member 8b is attached, and the four sides of the holding member 8a are bent to sandwich and fix the card clothing 3. Thus, it can be used as the slicker brush 8.

(25) Since the slicker brush 8 uses the card clothing 3 subjected to the second process, it can realize smooth combing and a beautiful finish, and also suppresses irritation to the skin of the target animal, and can prevent damages to be imparted to the skin.

(26) Furthermore, since it is possible to perform hair straightening by lightly pressing the pin tips on the skin of the animal, it contributes the health aspects of the animal such as blood circulation promotion due to the massage effect given to the skin and the reproduction prevention of bacteria due to removal of skin wastes. Although this point has conventionally been claimed in the slicker brush, in reality, because there is a risk that the distal ends of the pins may damage the skin, it is not used to press the pin tips on the animal, and it is an effect peculiar to the slicker brush 8 using the card clothing 3 according to the invention.

(27) The invention achieves the following effects by carrying out the first process and the second process illustrated in the embodiment.

(28) That is, as in the embodiment, by using the polishing material with flexibility and elasticity for the card clothing 3, it is possible to perform three-dimensional polishing in which remove burrs in the vicinity of the distal ends and give a rounded distal ends.

(29) As the polishing material used to exhibit the above-mentioned effect, as long as it is a base material having flexibility and elasticity, materials other than a non-woven fabric may be used.

(30) Further, by using the non-woven fabric 7b as a polishing material having flexibility and elasticity, due to the characteristics of the non-woven fabric 7b, such as a tissue structure intertwined without weaving fibers, the flexibility of the fibers, the hardness by providing polishing material particles, and the elasticity of the whole non-woven fabric, it is possible to perform three-dimensional polishing in which remove burrs in the vicinity of the distal ends of each pin and give a rounded distal ends, while preventing the scattering of polishing material or the entanglement of fibers to each pin 1.

(31) In addition, parameters such as pin implantation position and speed, polishing position and speed, and time required for polishing are set to appropriate values depending on the material of the card clothing 3 and the product standard of the card clothing 3, and the first and second processes are automated to enable a mass production of the card clothing 3 having a uniform shape and a polished state of the pin 1.

(32) Further, by using the non-woven fabric 7b of nylon, the strength of the non-woven fabric 7b can be enhanced, deterioration due to abrasion can be suppressed, and the non-woven fabric 7b can be used for a long time.

(33) In addition, since the polishing material particles are impregnated to the inside of the non-woven fabric 7b, the non-woven fabric 7b has an autogenous function, making it possible to maintain a constant polishing performance at all times.

(34) In addition, since the peripheral speed of the non-woven fabric roller 7 is set to 1×10.sup.4π to 3×10.sup.4π (mm/min), the time required for polishing is set to 20 to 60 (s), and the rotational distance of the non-woven fabric roller 7 required for polishing is set to 1×10.sup.4π (mm) or more, it is possible to perform three-dimensional polishing in which remove burrs in the vicinity of the distal ends and give a rounded distal ends with higher accuracy.

(35) Further, by making the width of the non-woven fabric roller 7 wider than the width of the base clothing 2 in the short direction, it is possible to arrange the card clothing 3 and the non-woven fabric roller 7 so that polishing of each pin 1 is performed by moving the base clothing 2 only in a single direction, and to simplify the manufacturing process.

Explanations of Letters or Numerals

(36) 1 PIN 2 BASE CLOTHING 2a SURFACE LAYER 2b BASE LAYER 3 CARD CLOTHING 4 PIN IMPLANTATION HOLE 5 AUTOMATIC PIN IMPLANTATION DEVICE 6 MECHANICAL TRANSPORT MEANS 7 NON-WOVEN FABRIC ROLLER 7a CYLINDRICAL ROLLER 7b NON-WOVEN FABRIC 8 SLICKER BRUSH 8a HOLDING MEMBER 8b HANDLE MEMBER