JP2000303334A - Felt and production of felt - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a felt which can effectively deodorize, even when ammonia is contained in an odor component, by integrally laminating a web comprising a fibrous material such as vegetable fibers or chemical fiber to a web comprising a fibrous ammonia adsorbent. SOLUTION: This felt is obtained by laminating the web of mixed fibrous materials to the web of a cotton-like ammonia adsorbent and/or the like and then passing the laminate through a needling process and/or a heating process. The mixed fibrous materials are obtained by mixing a fibrous material with 45 to 50 wt.% of the cotton-like ammonia adsorbent comprising the carbonization product of thin hair or ground hair thick growing on the seeds of cotton which is a plant belonging to the family Malvaceae, a powdery carbon material such as activated carbon or Bincho charcoal, or a powder ceramic material. The fibrous material comprises one or more of fibers selected from vegetable fibers and chemical fibers which have a luminosity of <6 in the Munsell color system, and thermally fusible fibers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a felt and a method for producing the felt, and more particularly to a felt and a method for producing the felt which can effectively adsorb ammonia which is an odor component.

[0002]

2. Description of the Related Art Conventionally, various felts having a deodorizing effect have been proposed. For example, JP-A-9-291500
And JP-A-9-188965 and JP-A-9-8
7955, JP-A-9-87953, and the like. These prior arts relate to felt (or nonwoven fabric) for the purpose of deodorizing effect or a method for producing the same.

[0003]

The odor components constituting the odor, needless to say, differ from one odor to another, and some odor components can achieve a high deodorizing effect even in the prior art. However, in the case where ammonia is contained in the odor component, the conventional technique cannot realize a sufficient deodorizing effect.

Accordingly, the present invention has been proposed to solve the above-mentioned problems of the conventional felt, and effectively eliminates odor even when ammonia is contained in the odor component. It is an object of the present invention to provide a felt and a method for manufacturing the felt that can be performed.

[0005]

Means for Solving the Problems The present invention has been proposed to solve the above problems, and the first invention (the invention according to claim 1) relates to felt, Ammonia adsorbent made of one or more fiber materials of fibers or chemical fibers, and inside, made of charcoal of fluff or ground hair densely growing on cotton seeds, which is a kind of malvaceous plant, and made into a cotton-like ammonia adsorbent Is characterized by containing.

As the fibers constituting the first invention, any one of plant fibers and chemical fibers may be used alone, or a plurality of fiber materials may be mixed and used.
In addition, cotton, hemp, and the like can be used as the plant fiber. Recycled fibers such as viscose rayon, copper ammonia rayon, and Tencel,
Semi-synthetic fibers such as acetate and triacetate, or synthetic fibers such as nylon, polyethylene terephthalate, polyacrylonitrile, polyvinyl alcohol, polyethylene, and polypropylene can be used.

As described above, the ammonia adsorbent constituting the first aspect of the present invention is made of a fluffy or ground wool charcoal which is densely grown on cotton seeds, which are a kind of malvaceae, and is formed into a floc. Yes, the manufacturing method is as follows. First, cotton fluff or ground hair is put into a carbonization device capable of controlling the flow rate of inert gas, and then
100-1000 degrees Celsius, preferably 300-60 degrees Celsius
Carbonization is performed at a temperature of 0 degree for 0.5 to 5 hours, preferably 1 to 3 hours. In addition, such a carbide does not need to be further activated, and it is not necessary to impregnate a substance that reacts with ammonia. Thus, it is possible to efficiently adsorb ammonia in this state and use it repeatedly. And, this ammonia adsorbing material,
pm in the gas phase, and about 1.0-2.0 wt.% in the liquid phase containing 2500 ppm ammonia.
If 0 to 5.0 wt% of ammonia is adsorbed and dried for about 1 hour at a temperature of about 100 degrees Celsius, ammonia can be adsorbed repeatedly with the same performance as the initial stage.

In the felt according to the first invention, not only the cotton-like ammonia adsorbent according to the above-described structure may be used alone, but also the second invention (the invention according to claim 2). As described above, a powdery carbon material such as activated carbon or Bincho charcoal or a powdery ceramic material such as silica gel or zeolite may be mixed and contained. By using these materials in combination, a deodorizing effect and a moisture absorbing effect can be further expected. The blending amount of the above-mentioned ammonia adsorbent may be about 45 to 55% of the whole, and is preferably about 50%. This is because if the amount is too small, the ability to adsorb ammonia decreases, and if the amount is too large, the possibility of falling off the felt increases and the tensile strength decreases.

The third invention (the invention according to claim 2)
According to the first or second aspect of the present invention, the color of the fiber material is lower than 6 in the Munsell color system. Here, "the brightness is lower than 6 in the Munsell color system" means "white" having the highest brightness or slightly lower than this "white" (9, 8, 7 in the Munsell color system). ) Does not include the color, and includes not only “black” having the lowest lightness but also “grey”, “brown”, and the like. As described above, by using a fiber material having a low brightness, the ammonia adsorbent, the carbon material, or the ceramic material contained therein can be significantly conspicuous even when exposed to the outside by performing needling described below. Absent. In particular, when the fiber material used is obtained from a large amount of waste as recycled, the chromaticity of the entire fiber material is relatively close to “black” or “grey”, and the ammonia adsorbent or carbon material described above is used. Etc. are `` black '' or a lightness close to it, so that both colors are close lightness, even if the ammonia adsorbent is exposed to the outside, it is prevented from being noticeable. By using this, the ammonia adsorbent can be used in a relatively large amount, and the effect of adsorbing ammonia can be further enhanced.

The fourth invention (the invention according to claim 3)
The present invention relates to a felt manufacturing method, and is a mixed fiber material obtained by mixing any one or a plurality of fiber materials of plant fibers or chemical fibers with a cotton-like carbon fiber material comprising the ammonia adsorbent according to claim 1. A first web forming step of forming a web from the first web forming step, and a second web forming step of forming a web from a flocculent carbon fiber material comprising the ammonia adsorbent according to claim 1. /
Or a web forming step including a third web forming step of forming a web from any one or a plurality of fiber materials of plant fibers or chemical fibers, and a web laminating step of laminating a plurality of webs formed by the web forming step And a heating step of heating the laminated web by needling the web laminated by the web laminating step and / or heating the laminated web.

It is to be noted that the web forming process constituting the fourth invention includes (1) a case where the process shifts to a web laminating process through only the first web forming process, and And (3) shifting to the web laminating step via the first web forming step and the third web generating step, and (3) shifting to the web laminating step via the first web forming step and the third web forming step. (4) This includes the case where the process proceeds to the web laminating process through the first web creating process, the second web creating process, and the third web creating process. Also,
In this web making process, the first to third
It is not necessary to perform the web forming steps in parallel. For example, the web forming step may be performed after the third web forming step, the first web forming step, and then the second web forming step.

The web laminating step is a step of laminating the webs produced in the web producing step. For example, the web produced in the first web producing step is laminated in a single layer or a plurality of layers. Thereafter, the web created in the second web creation step may be laminated in a single phase or a plurality of layers, and the web created in the first web creation step may be laminated in a single phase or a plurality of layers, Alternatively, the layers may be stacked in the reverse order. In addition, for example, the web created in the third web creation step is laminated in a single phase or a plurality of layers, and then the web created in the second web creation step is laminated in a single phase or a plurality of layers, Further, a web formed in the third web forming step or the first web forming step may be a single-phase or a plurality of layers laminated thereon. Further, during such a web laminating step, a carbon material such as activated carbon or Bincho charcoal described above, or a ceramic powder such as silica gel or zeolite may be laminated on each of the already laminated webs. In the web laminating step, not only the web created through the web creating step described above is laminated, but also materials other than the web may be laminated together with the web. For example, the web may be laminated on a urethane sheet or a thick woven fabric, or the urethane sheet or woven fabric may be laminated on the laminated web, and the web may be laminated thereon.

The web (web made of a cotton-like carbon fiber material made of the ammonia adsorbent according to the first aspect) produced in the second web making process constituting the web making process described above according to the present invention. When used as a felt material, a web laminated on the lower surface or the upper surface of the felt, wherein the web is formed in the first web forming step or the third web forming step (the ammonia according to claim 1). After previously laminating a web containing a fibrous material other than the flocculent carbon fiber material composed of the adsorbent, it is preferable to laminate the web created in the second web producing step. The number of webs to be laminated is 2 to
Preferably, ten webs are laminated. Moreover,
This pre-laminated web preferably laminates the web created in the third web creation step. This is because when the web created in the second web creation process is formed on one web, and the needling process is adopted in the subsequent process, the ammonia adsorbent according to claim 1 is used. This is because there is a risk of being exposed to the outside, and there is a possibility that a transfer device or a factory for transferring the web by dropping down through the web and transferring the web may be soiled.

A fifth invention (an invention according to claim 3)
In the third aspect of the present invention, the fibrous material used in the first web forming step or the third web forming step constituting the web forming step may include heat-fused fibers. It is a feature.

[0015] The heat-fused fiber constituting the fifth invention is:
For example, a monofilament or a composite fiber such as polypropylene or polyester may be used, and a fiber having a melting point lower than the melting point of other fiber materials must be used.

The heat-fused fiber constituting the fifth invention need not be contained in both the first web forming step and the web formed in the third web forming step. At least one of them may be included. Further, as the fiber material used in the first web forming step, only such heat-fused fibers may be used. For example, in a first web forming step, a web is formed using only such heat-fusible fibers as a material, and in a third web forming step, a web is formed without using heat-fusible fibers as a material. 2 to 10 layers of the web created in the third web creation step, and then 2 to 10 layers of the web created in the first web creation step, and the web created in the third web creation step May be laminated (web laminating step), and a felt may be manufactured through a needling step and a heating step. According to such a felt manufacturing method, the laminated webs are entangled with each other by the needling process, and the heat-fused fiber is heated and melted by the heating process and physically bonded to other fibers, thereby adsorbing ammonia. Not only can the material be prevented from falling off, but also the texture of the felt surface can be prevented from being deteriorated by the melting of the heat-fused fibers.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing felt according to each embodiment of the present invention will be described in detail, and thereafter, a felt manufactured by this manufacturing method will be described. First, the felt manufacturing method according to the first embodiment will be described in detail.

The felt manufactured in this embodiment is mainly used as a bed mat as bedding, and is made of a urethane sheet and a cotton-like polyester fiber which is both a chemical fiber and a heat-welded fiber. And carbon fiber which is an ammonia adsorbent (ammonia adsorbent made of fluffy or ground hair carbide that flourishes on cotton seeds, a kind of blue-crop plant) and bincho charcoal processed into powder It is. Therefore, a method for producing this felt will be described. First, 80% by weight of the polyester fiber and 20% by weight of the carbon fiber are mixed, and then the card material conventionally used from the mixed fiber material is used. A web is created (a first web creating step constituting the present invention). When the web was thus formed, the urethane sheet (40 g / m 2) was then placed on a transport path, and was processed into a powder on the urethane sheet 1 as shown in FIG. Stack Bincho charcoal 2. In this embodiment, the bincho charcoal 2 processed into powder is filled in a hopper 3 and formed at the lower end of the hopper 2 and discharged onto the urethane sheet 1 from an opening.

When the bincho charcoal 2 is laminated on the urethane sheet 1 as described above, then, as shown in FIG.
Ten webs 4 made from the mixed fiber material are laminated. Then, when the urethane sheet 1, the bincho charcoal 2, and the ten webs 4 (hereinafter, these are referred to as a laminate 5) are laminated in this order from the bottom, then needling is performed by a needle punch machine. As shown in FIG.
The needle punching machine 6 intermittently transports the laminate 5 in the transport direction, and when the laminate 5 is stopped, performs punching with a needle 7 having a notch (not shown) formed on the distal end or the peripheral surface of the distal end. Things. By the needling process by the needle punch machine 6, the ten webs 4 constituting the laminate 5 are entangled with each other, and the urethane sheet 1 and the web 4 are also entangled with each other, so that the laminate 5 is mechanically integrated. Be transformed into In addition, the powdery bincho charcoal 2 laminated between the urethane sheet 1 and the web 4 laminated at the bottom is in a state of being diffused slightly upward by the needling step.

According to the felt manufactured by the above-described manufacturing method, since the ammonia adsorbent is contained, even if ammonia is contained in the odor component in the air, it is removed. Effectively adsorbs, thus
It can provide a sufficient deodorizing effect and can be used as a bed mat to deodorize and eliminate odors caused by sweat and urine secreted from the user's body extremely effectively. Becomes In particular, since the felt according to this embodiment contains powdery Bincho charcoal, it is possible to sufficiently expect a moisture absorbing effect, and to absorb formaldehyde or hydrogen sulfide, which has recently become a problem in the building industry. Can also be done. Therefore, according to this felt, it is possible to use not only the bed mat described above but also an interior material or a heat insulating material installed on the wall of the building. Further, since the felt according to this embodiment is manufactured by the above-described method, the powdered Bincho charcoal formed on the urethane may be moved in one direction by being repeatedly used. Dropping from the felt can also be effectively prevented.

In the felt manufacturing method according to the first embodiment, the tentative manufacturing process is completed in the needling process, but the heating process is performed after the needling process. It may be. This heating step is performed by heating to a temperature equal to or around the melting point of the polyester fiber which is the material of the felt. When this heating step is adopted, a cooling step is performed immediately after heating. In the cooling step, an intake port is formed in the vicinity of the heated felt, and outside air is taken in from the intake port to cool the felt heated by the outside air. After completion of the needling step, by adopting such a heating step, the polyester fiber as the heat-welded fiber is melted and welded to the ammonia adsorbent as another fiber material, and the inside of the web 4 is formed by the needling step. It is also welded to the powdery Bincho charcoal that has been diffused to the sea. Therefore, according to the felt manufactured through this heating step, the tensile strength is increased, and the ammonia adsorbent and Bincho charcoal can be further prevented from falling off.

Next, a method for manufacturing a felt according to the second embodiment of the present invention will be described in detail. This second
The felt according to the embodiment is used as a heat insulating material as a shoe insole or a building material, a sheet body made of polyester fiber, and a cotton-like polyester which is a chemical fiber and a heat-welding fiber. Fiber, carbon fiber which is ammonia adsorbent (ammonia adsorbent made of fluffy and ground hair carbide that is densely grown on cotton seeds, which is a kind of Malvaceae plant), and bincho processed into powder It is charcoal. However, the above polyester fiber is the center (core)
Is melted at 220 degrees Celsius and the sheath formed around the core is a so-called core-sheath structure that melts at 110 to 200 degrees Celsius, and the polyester fiber, which is a material of the sheet body, Instead of such a core-sheath structure, it has a single structure that melts at 220 degrees Celsius.

Therefore, a method of manufacturing the felt according to the second embodiment will be described. First, 80% by weight of the polyester fiber and 20% by weight of the carbon fiber are mixed.
Next, a web is prepared from the mixed fiber material using a conventionally used card machine (first web forming step constituting the present invention). Then, when the web is created in this manner, the above-mentioned sheet body (40 g / m2)
Is placed on a transport path, and as shown in FIG. 4, seven webs 11 created by the card machine are stacked on the sheet body 10. Then, when the laminating step of the web 11 is completed, as shown in FIG. 5, the bincho charcoal 12 processed into a powdery state is laminated thereon by the same method as described in the first embodiment. I do.

When the step of laminating the powdery bincho charcoal 12 is completed, ten webs 11 produced in the above-mentioned web producing step are laminated. And
Thus, the sheet body 10, the seven webs 11, the bincho charcoal 12, and the ten webs 11 (hereinafter, these are referred to as a laminate 1
Say 3. ) Are sequentially stacked from the bottom, then a needling step is performed by a needle punching machine in the same manner as the method according to the first embodiment, and a heating step is further performed. In the heating step according to the second embodiment, heating is performed at a temperature of about 110 degrees Celsius.

According to the felt according to the second embodiment described above, compared to the felt according to the first embodiment, (the urethane sheet 1 is not used and the sheet member 10 made of polyester fiber is used as a constituent element. ),
Since it has good air permeability and is used as a shoe insole or as a heat insulating material as a building material as described above, it can absorb odor components in a very effective and high range. In addition, by employing the above-described heating step, only the sheath portion of the polyester fiber forming the web 11 is melted, so that the elasticity and the air permeability can be further improved, and the deodorizing effect can be further enhanced. be able to.

In the first and second embodiments, the components of the webs 4 and 11 are both mixed fibers obtained by mixing polyester fibers and carbon fibers as an ammonia adsorbent. The present invention is not such a component, but a mixed fiber obtained by mixing used carbon fiber with recycled fiber made by opening used or used fiber material and opening the used fiber material, or mixing the polyester fiber with such a mixed fiber. And create a web. Such recycled fibers have a lightness lower than 6 in the Munsell color system, and by making a web using the recycled fibers as a material, the powdery Bincho charcoal 2, 12 is externally exposed after the needling process. Even when exposed or moved near the surface, it is not noticeable.

In the felt according to the first and second embodiments, the felt is formed by laminating (containing) Bincho charcoal 2 and 12, but the present invention (the invention according to claim 1).
It is not always necessary to use such bincho charcoal as a constituent element, and it may be manufactured using only fiber material.In addition, instead of such bincho charcoal, powdered activated carbon may be used, or powdery ceramic material such as zeolite may be used. It may be a component. In each of the above embodiments, a mixed fiber of 80% by weight of a polyester fiber and 20% by weight of a carbon fiber as an ammonia adsorbent was used as a component of the web. However, the blending of these is not particularly limited. Not only that, a web is made from the above-mentioned carbon fiber alone as the ammonia adsorbent, and a web is made from a mixed fiber of, for example, 50% by weight of polyester fiber and 50% by weight of carbon fiber as the ammonia adsorbent. A single web may be laminated so as to be sandwiched between webs made of mixed fibers, and the process may be shifted to a subsequent step. Further, for example, a web is made of a mixed fiber of 50% by weight of polyester fiber and 50% by weight of carbon fiber as an ammonia adsorbent, and the web is laminated to obtain a felt used as a filter used in an air cleaner or the like. It may be manufactured.

[0028]

As is clear from the description of the felt and the method for manufacturing the felt according to the embodiment of the present invention described above, the present invention (the invention according to claim 1) internally includes:
Because it contains a cotton-like ammonia adsorbent made of fluff and ground hair carbide that is densely grown on cotton seeds, a kind of malvaceous plant, ammonia is much more efficient than conventionally proposed felt. Can be adsorbed, and thus a high deodorizing effect can be obtained.

Further, the second invention (the invention according to claim 2)
In the felt according to the present invention, since it is contained by being mixed with a powdery carbon material such as activated carbon or Bincho charcoal or a powdery ceramic material such as silica gel or zeolite, it is possible to expect a further deodorizing effect and a moisture absorbing effect. it can.

The third invention (the invention according to claim 3)
In the color of the fiber material, in the Munsell color system, since the lightness is lower than 6, the ammonia adsorbent and the powdery carbon material contained therein were exposed to the outside through the needling process. Even if it isn't noticeable. In particular, when the fiber material used is obtained from a large amount of waste as recycled, the chromaticity of the entire fiber material is relatively close to “black” or “grey”, and the ammonia adsorbent or carbon material described above is used. And the like are "black" or a lightness close to it, so that both colors have similar lightness, even if the ammonia adsorbent etc. is exposed to the outside, it is prevented from being noticeable, and furthermore, the fiber material of such a color By using, the ammonia adsorbent can be used in a relatively large amount, and the effect of adsorbing ammonia can be further enhanced.

The fourth invention (the invention according to claim 4)
According to the felt manufacturing method according to the fifth aspect, since the ammonia adsorbent is integrated with another fiber material, there is no possibility that the ammonia adsorbent will fall off due to use or be biased by its own weight. As in the case of the invention), when the heat-fused fibers are contained, the heat-fused fibers are heated and melted by the heating step and physically bonded to other fibers, so that the ammonia-adsorbing material or powdery It is possible to further prevent the carbon material and the ceramic material from falling off.

[Brief description of the drawings]

FIG. 1 is a side view schematically showing a state in which powdery bincho charcoal is laminated on a urethane sheet.

FIG. 2 is a side view schematically showing a state in which a web is laminated on the bincho charcoal shown in FIG.

FIG. 3 is a side view schematically showing a needling step.

FIG. 4 is a side view schematically showing a state in which a web is laminated on a sheet body.

FIG. 5 is a side view schematically showing a state in which powdery bincho charcoal is laminated on the web shown in FIG.

6 is a side view schematically showing a state in which a web is laminated on the bincho charcoal shown in FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Urethane sheet 2 Bincho charcoal 4 Web 6 Needle punch machine 10 Sheet body 11 Web 12 Bincho charcoal

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) D04H 1/54 D04H 1/54 B

Claims (5)

[Claims] 1. A cotton-like material which is made of one or more fiber materials of plant fiber or chemical fiber, and which is made of fluff or ground char which is densely grown on cotton seeds which are a kind of blue-green plants. Felt characterized by containing an ammonia adsorbent. 2. The felt according to claim 1, wherein a powdery carbon material or a powdery ceramic material is contained therein. 3. The color of the fiber material has a lightness lower than 6 in the Munsell color system.
Or the felt according to 2. 4. A first method for producing a web from a mixed fiber material obtained by mixing any one or a plurality of fiber materials of plant fibers or chemical fibers with the cotton-like carbon fiber material comprising the ammonia adsorbent according to claim 1. Or a first web forming step, a second web forming step of forming a web from a flocculent carbon fiber material comprising the ammonia adsorbent according to claim 1, and / or a vegetable fiber or a chemical fiber. A web forming step including a third web forming step of forming a web from any one or a plurality of fiber materials; a web laminating step of stacking a plurality of webs formed by the web forming step; A needling step of needling the web laminated by the step and / or a heating step of heating the laminated web. Manufacturing method of felt. 5. A fiber material used in the first web forming step or the third web forming step constituting the web forming step, wherein heat-fused fibers are included. Item 5. The method for producing felt according to Item 4.