US20180363167A1 - Method for Manufacturing a Resin Fiber and Nozzle Head and Manufacturing Device Used in Same - Google Patents
Method for Manufacturing a Resin Fiber and Nozzle Head and Manufacturing Device Used in Same Download PDFInfo
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- US20180363167A1 US20180363167A1 US15/571,367 US201715571367A US2018363167A1 US 20180363167 A1 US20180363167 A1 US 20180363167A1 US 201715571367 A US201715571367 A US 201715571367A US 2018363167 A1 US2018363167 A1 US 2018363167A1
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- Prior art keywords
- resin
- discharge port
- molten resin
- manufacturing
- gas flow
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D4/00—Spinnerette packs; Cleaning thereof
- D01D4/02—Spinnerettes
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D4/00—Spinnerette packs; Cleaning thereof
- D01D4/02—Spinnerettes
- D01D4/025—Melt-blowing or solution-blowing dies
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
- D01D5/098—Melt spinning methods with simultaneous stretching
- D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- 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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
Definitions
- the present invention relates to a method for manufacturing a resin fiber in which an extruded thermoplastic resin is stretched by high-pressure gas to form an aggregate of long fibers, and a nozzle head and a manufacturing device used in the same, and particularly relates to a method for manufacturing a resin fiber comprising an aggregate of long ultrafine fibers having a diameter in the nano-order, a manufacturing device, and a nozzle head used in the same.
- a resin fiber comprising an aggregate of long ultrafine fibers having a diameter of several microns to sub-microns is used in various filters and non-woven fabrics. While an electrospinning method has been proposed from long ago as a method for manufacturing such a resin fiber, in recent years many studies have been conducted on a melt-blowing method due to the enhanced productivity and safety thereof. In such a melt-blowing method, a thermoplastic resin extruded from an extruder is emitted into the air by blowing high-pressure gas using a nozzle part, forming an aggregate of long fibers (refer to Non-Patent Document 1).
- Patent Document 1 discloses a method for manufacturing a resin fiber comprising an aggregate of long ultrafine polypropylene fibers based on a melt-blowing method.
- Example 2 a tip of a center discharge port through which a molten resin is extruded is surrounded by a hot air blowout port, the molten resin is stretched while the melted state of the resin is maintained inside a hot air converging cylindrical part extending downstream, the resin is emitted from an opening into the air, and an aggregate of long fibers is collected by a collecting part disposed in a horizontal direction.
- a diameter of the center discharge port should be 0.1 to 0.2 mm, with the melted state for stretching the resin in the hot air converging cylindrical part being controlled, it is stated that, depending on the inner diameter or adjustment of the temperature of the interior, discharge is no longer possible or only ultrafine fibers of a micron-order can be obtained.
- Patent Document 2 also discloses a method for manufacturing a resin fiber comprising an aggregate of long ultrafine thermoplastic resin fibers based on a melt-blowing method.
- a plurality of small molten resin spray ports is provided around a most-expanded diameter opening through which a gas heated to a temperature higher than the temperature of a molten resin is sprayed outside the device in a horizontal direction, and a molten resin sprayed upon pressurization is engulfed in a flow of a gas sprayed from a gas spray port and then sprayed outside the device from the most-expanded diameter opening, stretching the molten resin in the spraying direction.
- Patent Document 2 describes a 3-mm tube diameter of the molten resin spray port being decreased to 0.4 mm to apply pressure, and a gas being sprayed from the gas spray port having a 2-mm diameter and then ejected outside the device from the most-expanded diameter opening having a 22-mm diameter.
- thermoplastic resin fiber In a method for manufacturing long ultrafine thermoplastic resin fiber based on a melt-blowing method, the resin is stretched, decreasing the diameter thereof. While the production volume can be increased based on high operability by safely controlling such a resin stretching step, in Patent Document 1 the hot air converging cylindrical part is provided in order to isolate the stretching step from the outside, and in Patent Document 2 a high-temperature gas flow having a heat capacity greater than a capacity of the resin is formed and the resin is sprayed therein, isolating the sprayed resin from the outside.
- the present invention was made in light of such circumstances, and it is therefore an object of the present invention to provide a method for manufacturing a resin fiber capable of significantly increasing a production volume based on high operability, and a nozzle head and a manufacturing device used in the same.
- a method for manufacturing a resin fiber according to the present invention is a method for manufacturing a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, the method comprising the steps of applying a negative pressure of a gas flow from a high-pressure gas ejection port provided near a discharge port through which a molten resin is extruded to the discharge port, externally extracting the molten resin inside the discharge port, and emitting the molten resin into the air while stretching the molten resin.
- the molten resin that remains inside the discharge port may be externally extracted and stretched by a negative pressure even when the molten resin extruded from the discharge port is supplied from an extruder and the supply of the molten resin from the extruder is stopped. According to such an invention, it is possible to reliably extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow from the high-pressure gas ejection port.
- the discharge port may have a diameter that decreases a flow resistance of the molten resin so that the molten resin can be extracted by the negative pressure resulting from the gas flow.
- the diameter of the discharge port may be 0.5 mm or greater. According to such an invention, it is possible to reliably extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow from the high-pressure gas ejection port, and further increase the production volume.
- a manufacturing device of a resin fiber according to the present invention is a manufacturing device of a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, comprising an extruder that extrudes a molten resin from a nozzle on a tip of a barrel while melting the resin using a screw in the barrel, and a nozzle head attached to a tip of the nozzle.
- the nozzle head is provided with a plurality of pairs of a discharge port that extrudes the molten resin and a high-pressure gas ejection port that is near the discharge port and forms a substantially horizontal gas flow, on a substantially vertical face.
- the high-pressure gas ejection port is positioned near the discharge port and the discharge port has a diameter set to 0.5 mm or greater so that the molten resin inside the discharge port is externally extracted and emitted into the air while stretched.
- the plurality of pairs may be provided on the face along a horizontal line. Further, in the invention described above, the high-pressure gas ejection ports of the plurality of pairs may be provided so that the respective axes are mutually spread into a fan shape toward an ejection direction. According to such an invention, the production volume can be further increased based on high operability.
- a nozzle head is a nozzle head used in an extruder that extrudes a molten resin from a nozzle on a tip of a barrel while melting the resin using a screw in the barrel in a manufacturing device of a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, and attached to a tip of the nozzle.
- the nozzle head is provided with a plurality of pairs of a discharge port that extrudes the molten resin and a high-pressure gas ejection port that is near the discharge port and forms a substantially horizontal gas flow, on a substantially vertical face when attached to the manufacturing device.
- the high-pressure gas ejection port is positioned near the discharge port and the discharge port has a diameter set to 0.5 mm or greater so that the molten resin inside the discharge port is externally extracted and emitted into the air while stretched.
- the nozzle head is attached to a manufacturing device of a resin fiber, making it possible to extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow, stabilize operation, and achieve high operability by simply adjusting the amount of gas flow in accordance with the extruded amount of resin. Further, the extruded amount is increased, making it possible to significantly increase the production volume.
- the plurality of pairs may be provided on the face so as to extend along the horizontal line when the nozzle head is attached to the manufacturing device. Further, in the invention described above, the high-pressure gas ejection ports of the plurality of pairs may be provided so that the respective axes are mutually spread into a fan shape toward the ejection direction. According to such an invention, the production volume can be further increased based on high operability.
- FIG. 1 is a cross-sectional view (partial block diagram) of a main portion of a manufacturing device of a resin fiber in one example according to the present invention.
- FIGS. 2A and 2B are a front view and a side cross-sectional view of a nozzle head, respectively.
- FIGS. 3A and 3B are top cross-sectional views of a nozzle head.
- FIG. 4 is a scanning electron microscope (SEM) image of a resin fiber manufactured by the manufacturing device of a resin fiber.
- FIGS. 1 to 4 A manufacturing device of a resin fiber will now be described as one example according to the present invention using FIGS. 1 to 4 .
- a manufacturing device 9 of a resin fiber is a manufacturing device of a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, and includes an extruder 1 that extrudes a melted resin from a nozzle 2 a , and a nozzle head 10 attached to a tip of the nozzle 2 a.
- the extruder 1 includes a barrel 2 and a screw 3 that knead and transport a raw material such as a pellet made from a thermoplastic resin toward the nozzle 2 a while heating and melting the raw material, and a hopper 4 for supplying the raw material to an interior of the barrel 2 .
- the barrel 2 comprises a heater 5 on an outer periphery thereof, making it possible to heat the interior.
- the nozzle head 10 for discharging a resin is fixed to the tip of the nozzle 2 a provided in an extrusion direction of the resin of the barrel 2 .
- the nozzle head 10 is configured so as to be connected to a gas heating part 7 by piping or the like, and a high-pressure gas supplied from a gas supply part 6 such as a gas compressor connected to an end thereof is heated and then supplied.
- the gas heating part 7 can comprise a heating part such as a heater around a gas pressure-feeding tube, for example.
- the nozzle head 10 includes an attaching part 19 on an outer peripheral side for attaching the nozzle head 10 to the extruder 1 , and a face part 11 on a center side where a main surface is disposed substantially vertically (a normal line of the main surface is directed horizontally) when the nozzle head 10 is attached to the extruder 1 .
- the attaching part 19 comprises a bolt hole or the like (not illustrated) for fixing the nozzle head 10 to the extruder 1 .
- the face part 11 is provided so as to protrude in an extrusion direction of the resin with respect to the attaching part 19 .
- the face part 11 is further provided with a discharge port 12 that discharges a resin, and a gas ejection port 13 that ejects high-pressure gas.
- the discharge port 12 and the gas ejection port 13 form a pair with one of each disposed near each other.
- a plurality of pairs of the discharge port 12 and the gas ejection port 13 are provided. Providing such a plurality of pairs can improve the production volume of resin fiber per unit time, and is thus preferred.
- the discharge port 12 communicates with a resin inflow chamber 16 .
- the resin inflow chamber 16 is positioned in the extrusion direction of the resin with respect to the nozzle 2 a of the barrel 2 when the nozzle head 10 is attached to the extruder 1 , thereby forming a flow path of the melted resin supplied from the nozzle 2 a and making it possible to guide the melted resin to the discharge ports 12 .
- the resin inflow chamber 16 is separated by a partition 15 from a gas inflow chamber 14 that forms a gas flow path.
- the gas inflow chamber 14 is connected to the gas ejection ports 13 , and to an inflow port 14 a of a high-pressure gas guided from outside the nozzle head 10 .
- the inflow port 14 a is connected to the gas heating part 7 described above.
- the gas inflow chamber 14 can guide the entered high-pressure gas to the gas ejection ports 13 .
- the axis of the gas ejection port 13 is disposed substantially horizontally so that the gas flow is formed substantially in the horizontal direction by the ejected high-pressure gas.
- the discharge ports 12 are also each preferably disposed substantially in the horizontal direction in line with the orientation of the gas ejection port 13 that forms the pair.
- the gas ejection port 13 is disposed near the discharge port 12 as described above.
- the gas ejection port 13 is disposed near the discharge port 12 so that the melted resin can be externally extracted from inside the discharge port 12 by the negative pressure generated by the formed gas flow, and emitted into the air while stretched.
- an inner diameter of the discharge port 12 is set so that a flow resistance of the melted resin is decreased, and the resin is extracted from the interior by a negative pressure resulting from the gas flow.
- the flow resistance of the melted resin decreases as the size of the inner diameter is increased.
- an inner diameter of an outlet section of the discharge port 12 is preferably 0.5 mm or greater.
- the inner diameter of the discharge port 12 is 1.0 mm
- the inner diameter of the gas ejection port 13 is 1.5 mm
- the distance between the centers thereof is 1.75 mm.
- the gas ejection port 13 can be disposed in any direction, regardless if above, below, or next to the discharge port 12 .
- pairs with the gas ejection port 13 disposed below the discharge port 12 are arranged in an upper row, and pairs with the gas ejection port 13 disposed above the discharge port 12 are arranged in a lower row on the face part 11 .
- the axes of the gas ejection ports 13 are provided so as to be mutually spread into a fan shape toward the ejection direction (upward in the drawing) in a horizontal plane.
- the axes of the gas ejection ports 13 on both ends overlap both radii of a center angle a having a fan shape enclosed by two radii and an arc, and the axes of the other ejection ports 13 are also disposed so as to pass through a center point where the two radii of the same fan shape intersect.
- the axes of the discharge ports 12 are provided so as to be mutually spread into a fan shape toward the discharge direction. With such an arrangement, adjustments can be made so as to suppress excessive intertwining between the resin fibers extracted from the respective pairs and emitted into the air, making it possible to increase the discharge amount of resin per unit time and increase the production volume per unit time, and thus such an arrangement is preferred.
- the manufacturing device 9 suitably comprises a collecting part for collecting the emitted resin fiber.
- the resin fiber can be manufactured by one type of melt-blowing method in which the molten resin is emitted into the air and stretched while cooled. At this time, operation can be easily stabilized by making the extruded amount of the resin uniform and adjusting the amount of gas flow in accordance with the extruded amount.
- a resin fiber is continuously manufactured for some time by simply supplying the high-pressure gas even if the supply of the melted resin from the extruder 1 is stopped during the manufacture of the resin fiber. That is, the resin that remains inside the discharge ports 12 is found to be reliably externally extracted and stretched by the negative pressure resulting from the gas flow from the gas ejection ports 13 .
- the resin fiber manufactured by the manufacturing device 9 is found to be a long ultrafine fiber such as a so-called nanofiber that has a diameter of about the micron order to several hundred nanometers. Further, the resin fibers moderately intertwine, and short, divided fiber and particulate resin are substantially not produced.
- the manufacturing device 9 it is possible to manufacture a resin fiber that is a long ultrafine fiber by extracting a resin melted in the discharge ports 12 and emitting the resin into the air by the negative pressure resulting from the gas flow from the gas ejection ports 13 , and thus stretching while cooling the resin.
- the resin is thus extracted from the discharge ports 12 , thereby making it possible to stabilize operation and achieve high operability by simply adjusting the amount of gas flow in accordance with the extruded amount of the resin from the extruder 1 .
- the manufacturing device 9 can manufacture a long ultrafine fiber such as a nanofiber
- the inner diameter of the discharge port 12 is extremely large compared to the fiber diameter, and is set to 1 mm in this example as described above. That is, the diameter of the resin fiber manufactured by the manufacturing device 9 is considered to not be dependent on the diameter of the discharge ports 12 , but rather dependent on a balance between the gas flow from the ejection ports 13 and the amount of resin supplied. That is, the flow rate and the negative pressure from the ejection ports 13 are adjusted by adjusting the amount of gas flow in accordance with the amount of melted resin to be supplied. As a result, it is considered that the amount of extracted resin is adjusted, and the diameter is adjusted by the relationship with the gas flow rate.
- a long ultrafine fiber having a preferred diameter can be manufactured by balancing the amount of gas flow in accordance with the amount of melted resin to be supplied.
- the diameter of the discharge ports 12 is made relatively large to decrease the flow resistance of the melted resin and facilitate the extraction of such a molten resin as described above. Further, it is easy to increase the discharge amount of the resin by relatively increasing the diameter of the discharge ports 12 , and further increase the production volume per unit time by adjusting the amount of gas flow in accordance with this increase.
- the diameter of the discharge ports 12 is large, resulting in minimal clogging as well as extremely easy maintenance.
- the production volume per unit time can be increased by further increasing the number of pairs of the discharge port 12 and the gas ejection port 13 of the nozzle head 10 by providing, for example, three or more rows of a plurality of pairs on the face part 11 .
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
- Nonwoven Fabrics (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
Description
- The present invention relates to a method for manufacturing a resin fiber in which an extruded thermoplastic resin is stretched by high-pressure gas to form an aggregate of long fibers, and a nozzle head and a manufacturing device used in the same, and particularly relates to a method for manufacturing a resin fiber comprising an aggregate of long ultrafine fibers having a diameter in the nano-order, a manufacturing device, and a nozzle head used in the same.
- A resin fiber comprising an aggregate of long ultrafine fibers having a diameter of several microns to sub-microns is used in various filters and non-woven fabrics. While an electrospinning method has been proposed from long ago as a method for manufacturing such a resin fiber, in recent years many studies have been conducted on a melt-blowing method due to the enhanced productivity and safety thereof. In such a melt-blowing method, a thermoplastic resin extruded from an extruder is emitted into the air by blowing high-pressure gas using a nozzle part, forming an aggregate of long fibers (refer to Non-Patent Document 1).
- For example, Patent Document 1 discloses a method for manufacturing a resin fiber comprising an aggregate of long ultrafine polypropylene fibers based on a melt-blowing method. In Example 2 thereof, a tip of a center discharge port through which a molten resin is extruded is surrounded by a hot air blowout port, the molten resin is stretched while the melted state of the resin is maintained inside a hot air converging cylindrical part extending downstream, the resin is emitted from an opening into the air, and an aggregate of long fibers is collected by a collecting part disposed in a horizontal direction. Here, while a diameter of the center discharge port should be 0.1 to 0.2 mm, with the melted state for stretching the resin in the hot air converging cylindrical part being controlled, it is stated that, depending on the inner diameter or adjustment of the temperature of the interior, discharge is no longer possible or only ultrafine fibers of a micron-order can be obtained.
- Furthermore,
Patent Document 2 also discloses a method for manufacturing a resin fiber comprising an aggregate of long ultrafine thermoplastic resin fibers based on a melt-blowing method. A plurality of small molten resin spray ports is provided around a most-expanded diameter opening through which a gas heated to a temperature higher than the temperature of a molten resin is sprayed outside the device in a horizontal direction, and a molten resin sprayed upon pressurization is engulfed in a flow of a gas sprayed from a gas spray port and then sprayed outside the device from the most-expanded diameter opening, stretching the molten resin in the spraying direction. Here, as one example,Patent Document 2 describes a 3-mm tube diameter of the molten resin spray port being decreased to 0.4 mm to apply pressure, and a gas being sprayed from the gas spray port having a 2-mm diameter and then ejected outside the device from the most-expanded diameter opening having a 22-mm diameter. -
- Non-Patent Document 1: Kunihiro Shinji, “Nanofiber no Sekai (The World of Nanofibers)”, Japan Electrical Insulating and Advanced Performance Materials Industrial Association, Denzai Journal, No. 626, 2015.5, PP.16-18
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- Patent Document 1: Japanese Laid-Open Patent Application No. 2013-185272
- Patent Document 2: Japanese Laid-Open Patent Application No. 2016-23399
- In a method for manufacturing long ultrafine thermoplastic resin fiber based on a melt-blowing method, the resin is stretched, decreasing the diameter thereof. While the production volume can be increased based on high operability by safely controlling such a resin stretching step, in Patent Document 1 the hot air converging cylindrical part is provided in order to isolate the stretching step from the outside, and in
Patent Document 2 a high-temperature gas flow having a heat capacity greater than a capacity of the resin is formed and the resin is sprayed therein, isolating the sprayed resin from the outside. - The present invention was made in light of such circumstances, and it is therefore an object of the present invention to provide a method for manufacturing a resin fiber capable of significantly increasing a production volume based on high operability, and a nozzle head and a manufacturing device used in the same.
- A method for manufacturing a resin fiber according to the present invention is a method for manufacturing a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, the method comprising the steps of applying a negative pressure of a gas flow from a high-pressure gas ejection port provided near a discharge port through which a molten resin is extruded to the discharge port, externally extracting the molten resin inside the discharge port, and emitting the molten resin into the air while stretching the molten resin.
- According to such an invention, while the molten resin is extracted and stretched into a long ultrafine fiber by a negative pressure resulting from the gas flow, it is easy to stabilize operation, achieve high operability, and increase the extruded amount by simply adjusting the gas flow in accordance with the extruded amount of resin, making it possible to significantly increase the production volume based on high operability.
- In the invention described above, the molten resin that remains inside the discharge port may be externally extracted and stretched by a negative pressure even when the molten resin extruded from the discharge port is supplied from an extruder and the supply of the molten resin from the extruder is stopped. According to such an invention, it is possible to reliably extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow from the high-pressure gas ejection port.
- In the invention described above, the discharge port may have a diameter that decreases a flow resistance of the molten resin so that the molten resin can be extracted by the negative pressure resulting from the gas flow. Further, in the invention described above, the diameter of the discharge port may be 0.5 mm or greater. According to such an invention, it is possible to reliably extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow from the high-pressure gas ejection port, and further increase the production volume.
- Furthermore, a manufacturing device of a resin fiber according to the present invention is a manufacturing device of a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, comprising an extruder that extrudes a molten resin from a nozzle on a tip of a barrel while melting the resin using a screw in the barrel, and a nozzle head attached to a tip of the nozzle. The nozzle head is provided with a plurality of pairs of a discharge port that extrudes the molten resin and a high-pressure gas ejection port that is near the discharge port and forms a substantially horizontal gas flow, on a substantially vertical face. The high-pressure gas ejection port is positioned near the discharge port and the discharge port has a diameter set to 0.5 mm or greater so that the molten resin inside the discharge port is externally extracted and emitted into the air while stretched.
- According to such an invention, it is possible to extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow, stabilize operation, achieve high operability, and increase the extruded amount by simply adjusting the amount of the gas flow in accordance with the extruded amount of resin, and thus significantly increase the production volume.
- In the invention described above, the plurality of pairs may be provided on the face along a horizontal line. Further, in the invention described above, the high-pressure gas ejection ports of the plurality of pairs may be provided so that the respective axes are mutually spread into a fan shape toward an ejection direction. According to such an invention, the production volume can be further increased based on high operability.
- Furthermore, a nozzle head according to the present invention is a nozzle head used in an extruder that extrudes a molten resin from a nozzle on a tip of a barrel while melting the resin using a screw in the barrel in a manufacturing device of a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, and attached to a tip of the nozzle. The nozzle head is provided with a plurality of pairs of a discharge port that extrudes the molten resin and a high-pressure gas ejection port that is near the discharge port and forms a substantially horizontal gas flow, on a substantially vertical face when attached to the manufacturing device. The high-pressure gas ejection port is positioned near the discharge port and the discharge port has a diameter set to 0.5 mm or greater so that the molten resin inside the discharge port is externally extracted and emitted into the air while stretched.
- According to such an invention, the nozzle head is attached to a manufacturing device of a resin fiber, making it possible to extract and stretch the molten resin into a long ultrafine fiber by the negative pressure resulting from the gas flow, stabilize operation, and achieve high operability by simply adjusting the amount of gas flow in accordance with the extruded amount of resin. Further, the extruded amount is increased, making it possible to significantly increase the production volume.
- In the invention described above, the plurality of pairs may be provided on the face so as to extend along the horizontal line when the nozzle head is attached to the manufacturing device. Further, in the invention described above, the high-pressure gas ejection ports of the plurality of pairs may be provided so that the respective axes are mutually spread into a fan shape toward the ejection direction. According to such an invention, the production volume can be further increased based on high operability.
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FIG. 1 is a cross-sectional view (partial block diagram) of a main portion of a manufacturing device of a resin fiber in one example according to the present invention. -
FIGS. 2A and 2B are a front view and a side cross-sectional view of a nozzle head, respectively. -
FIGS. 3A and 3B are top cross-sectional views of a nozzle head. -
FIG. 4 is a scanning electron microscope (SEM) image of a resin fiber manufactured by the manufacturing device of a resin fiber. - A manufacturing device of a resin fiber will now be described as one example according to the present invention using
FIGS. 1 to 4 . - As illustrated in
FIG. 1 , amanufacturing device 9 of a resin fiber is a manufacturing device of a resin fiber that is a long ultrafine fiber obtained by stretching a thermoplastic resin by a high-pressure gas flow, and includes an extruder 1 that extrudes a melted resin from anozzle 2 a, and anozzle head 10 attached to a tip of thenozzle 2 a. - The extruder 1 includes a
barrel 2 and ascrew 3 that knead and transport a raw material such as a pellet made from a thermoplastic resin toward thenozzle 2 a while heating and melting the raw material, and ahopper 4 for supplying the raw material to an interior of thebarrel 2. Further, thebarrel 2 comprises aheater 5 on an outer periphery thereof, making it possible to heat the interior. Thenozzle head 10 for discharging a resin is fixed to the tip of thenozzle 2 a provided in an extrusion direction of the resin of thebarrel 2. Thenozzle head 10 is configured so as to be connected to agas heating part 7 by piping or the like, and a high-pressure gas supplied from agas supply part 6 such as a gas compressor connected to an end thereof is heated and then supplied. Thegas heating part 7 can comprise a heating part such as a heater around a gas pressure-feeding tube, for example. - As illustrated in
FIGS. 2A and 2B , thenozzle head 10 includes an attachingpart 19 on an outer peripheral side for attaching thenozzle head 10 to the extruder 1, and aface part 11 on a center side where a main surface is disposed substantially vertically (a normal line of the main surface is directed horizontally) when thenozzle head 10 is attached to the extruder 1. The attachingpart 19 comprises a bolt hole or the like (not illustrated) for fixing thenozzle head 10 to the extruder 1. Further, theface part 11 is provided so as to protrude in an extrusion direction of the resin with respect to the attachingpart 19. - The
face part 11 is further provided with adischarge port 12 that discharges a resin, and agas ejection port 13 that ejects high-pressure gas. Thedischarge port 12 and thegas ejection port 13 form a pair with one of each disposed near each other. In this example, a plurality of pairs of thedischarge port 12 and thegas ejection port 13 are provided. Providing such a plurality of pairs can improve the production volume of resin fiber per unit time, and is thus preferred. - The
discharge port 12 communicates with aresin inflow chamber 16. Theresin inflow chamber 16 is positioned in the extrusion direction of the resin with respect to thenozzle 2 a of thebarrel 2 when thenozzle head 10 is attached to the extruder 1, thereby forming a flow path of the melted resin supplied from thenozzle 2 a and making it possible to guide the melted resin to thedischarge ports 12. Theresin inflow chamber 16 is separated by apartition 15 from agas inflow chamber 14 that forms a gas flow path. Thegas inflow chamber 14 is connected to thegas ejection ports 13, and to aninflow port 14a of a high-pressure gas guided from outside thenozzle head 10. It should be noted that theinflow port 14a is connected to thegas heating part 7 described above. As a result, thegas inflow chamber 14 can guide the entered high-pressure gas to thegas ejection ports 13. Further, the axis of thegas ejection port 13 is disposed substantially horizontally so that the gas flow is formed substantially in the horizontal direction by the ejected high-pressure gas. Thedischarge ports 12 are also each preferably disposed substantially in the horizontal direction in line with the orientation of thegas ejection port 13 that forms the pair. - The
gas ejection port 13 is disposed near thedischarge port 12 as described above. In particular, thegas ejection port 13 is disposed near thedischarge port 12 so that the melted resin can be externally extracted from inside thedischarge port 12 by the negative pressure generated by the formed gas flow, and emitted into the air while stretched. Further, an inner diameter of thedischarge port 12 is set so that a flow resistance of the melted resin is decreased, and the resin is extracted from the interior by a negative pressure resulting from the gas flow. The flow resistance of the melted resin decreases as the size of the inner diameter is increased. For example, an inner diameter of an outlet section of the discharge port 12 (near the surface of the face part 11) is preferably 0.5 mm or greater. In this example, the inner diameter of thedischarge port 12 is 1.0 mm, the inner diameter of thegas ejection port 13 is 1.5 mm, and the distance between the centers thereof is 1.75 mm. - It should be noted that, as long as the resin can be extracted by the negative pressure as described above, the
gas ejection port 13 can be disposed in any direction, regardless if above, below, or next to thedischarge port 12. In this example, pairs with thegas ejection port 13 disposed below thedischarge port 12 are arranged in an upper row, and pairs with thegas ejection port 13 disposed above thedischarge port 12 are arranged in a lower row on theface part 11. - As illustrated in
FIGS. 3A and 3B , in the plurality of pairs of thedischarge port 12 and thegas ejection port 13 arranged in the lower row on theface part 11, the axes of thegas ejection ports 13 are provided so as to be mutually spread into a fan shape toward the ejection direction (upward in the drawing) in a horizontal plane. For example, the axes of thegas ejection ports 13 on both ends overlap both radii of a center angle a having a fan shape enclosed by two radii and an arc, and the axes of theother ejection ports 13 are also disposed so as to pass through a center point where the two radii of the same fan shape intersect. Similarly, the axes of thedischarge ports 12 are provided so as to be mutually spread into a fan shape toward the discharge direction. With such an arrangement, adjustments can be made so as to suppress excessive intertwining between the resin fibers extracted from the respective pairs and emitted into the air, making it possible to increase the discharge amount of resin per unit time and increase the production volume per unit time, and thus such an arrangement is preferred. The same applies to the plurality of pairs of thedischarge port 12 and thegas ejection port 13 arranged in the upper row on theface part 11. - It should be noted that the other details of the extruder 1 are publicly known, and a description thereof is omitted. Further, the
manufacturing device 9 suitably comprises a collecting part for collecting the emitted resin fiber. - With reference to
FIG. 1 once again, when a resin fiber is manufactured by themanufacturing device 9, high-pressure gas heated by thegas supply part 6 and thegas heating part 7 is supplied to thenozzle head 10 and ejected from thegas ejection ports 13 to form a gas flow while the resin melted by the extruder 1 is supplied to thenozzle head 10 and discharged from thedischarge ports 12. As a result, the gas flow from thegas ejection ports 13 applies a negative pressure to a frontward side of thedischarge ports 12, causing the molten resin inside thedischarge ports 12 to be externally extracted and emitted into the air while stretched into a long ultrafine fiber. That is, the resin fiber can be manufactured by one type of melt-blowing method in which the molten resin is emitted into the air and stretched while cooled. At this time, operation can be easily stabilized by making the extruded amount of the resin uniform and adjusting the amount of gas flow in accordance with the extruded amount. - In particular, a resin fiber is continuously manufactured for some time by simply supplying the high-pressure gas even if the supply of the melted resin from the extruder 1 is stopped during the manufacture of the resin fiber. That is, the resin that remains inside the
discharge ports 12 is found to be reliably externally extracted and stretched by the negative pressure resulting from the gas flow from thegas ejection ports 13. - As shown in
FIG. 4 , the resin fiber manufactured by themanufacturing device 9 is found to be a long ultrafine fiber such as a so-called nanofiber that has a diameter of about the micron order to several hundred nanometers. Further, the resin fibers moderately intertwine, and short, divided fiber and particulate resin are substantially not produced. - Thus, according to the
manufacturing device 9, it is possible to manufacture a resin fiber that is a long ultrafine fiber by extracting a resin melted in thedischarge ports 12 and emitting the resin into the air by the negative pressure resulting from the gas flow from thegas ejection ports 13, and thus stretching while cooling the resin. The resin is thus extracted from thedischarge ports 12, thereby making it possible to stabilize operation and achieve high operability by simply adjusting the amount of gas flow in accordance with the extruded amount of the resin from the extruder 1. As described above, even when a plurality of pairs of thedischarge port 12 and thegas ejection port 13 is arranged or the like and the discharge amount of resin is increased, it is possible to significantly increase the production volume based on high productivity as long as the amount of gas flow is adjusted in accordance with the increase. - Further, while the
manufacturing device 9 can manufacture a long ultrafine fiber such as a nanofiber, the inner diameter of thedischarge port 12 is extremely large compared to the fiber diameter, and is set to 1 mm in this example as described above. That is, the diameter of the resin fiber manufactured by themanufacturing device 9 is considered to not be dependent on the diameter of thedischarge ports 12, but rather dependent on a balance between the gas flow from theejection ports 13 and the amount of resin supplied. That is, the flow rate and the negative pressure from theejection ports 13 are adjusted by adjusting the amount of gas flow in accordance with the amount of melted resin to be supplied. As a result, it is considered that the amount of extracted resin is adjusted, and the diameter is adjusted by the relationship with the gas flow rate. A long ultrafine fiber having a preferred diameter can be manufactured by balancing the amount of gas flow in accordance with the amount of melted resin to be supplied. Thus, preferably the diameter of thedischarge ports 12 is made relatively large to decrease the flow resistance of the melted resin and facilitate the extraction of such a molten resin as described above. Further, it is easy to increase the discharge amount of the resin by relatively increasing the diameter of thedischarge ports 12, and further increase the production volume per unit time by adjusting the amount of gas flow in accordance with this increase. - It should be noted that the diameter of the
discharge ports 12 is large, resulting in minimal clogging as well as extremely easy maintenance. - Further, the production volume per unit time can be increased by further increasing the number of pairs of the
discharge port 12 and thegas ejection port 13 of thenozzle head 10 by providing, for example, three or more rows of a plurality of pairs on theface part 11. - While the above has described examples according to the present invention and modifications based on these, the present invention is not necessarily limited thereto. Further, those skilled in the art may conceive various alternative examples and modified examples without departing from the spirit or the appended claims of the present invention.
-
- 10 Nozzle head
- 11 Face part
- 12 Discharge port
- 13 Gas ejection port
Claims (12)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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JP2016-221401 | 2016-11-14 | ||
JP2016221401A JP6171072B1 (en) | 2016-11-14 | 2016-11-14 | Resin fiber manufacturing method, nozzle head and manufacturing apparatus used therefor |
PCT/JP2017/030936 WO2018087993A1 (en) | 2016-11-14 | 2017-08-29 | Method for manufacturing resin fiber, nozzle head used in same, and manufacturing device |
Publications (1)
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US20180363167A1 true US20180363167A1 (en) | 2018-12-20 |
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ID=59384400
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US15/571,367 Abandoned US20180363167A1 (en) | 2016-11-14 | 2017-08-29 | Method for Manufacturing a Resin Fiber and Nozzle Head and Manufacturing Device Used in Same |
Country Status (5)
Country | Link |
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US (1) | US20180363167A1 (en) |
JP (1) | JP6171072B1 (en) |
CN (1) | CN108323175B (en) |
TW (1) | TWI628322B (en) |
WO (1) | WO2018087993A1 (en) |
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CN110341156A (en) * | 2019-07-02 | 2019-10-18 | 上海建沪鸿达科技有限公司 | A kind of device using high pressure draught production nano-resin fiber |
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- 2017-08-29 WO PCT/JP2017/030936 patent/WO2018087993A1/en active Application Filing
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Also Published As
Publication number | Publication date |
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JP6171072B1 (en) | 2017-07-26 |
CN108323175B (en) | 2021-10-01 |
WO2018087993A1 (en) | 2018-05-17 |
TWI628322B (en) | 2018-07-01 |
CN108323175A (en) | 2018-07-24 |
JP2018080405A (en) | 2018-05-24 |
TW201821660A (en) | 2018-06-16 |
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