JP2001049562A - Nonwoven fabric, method and apparatus for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a nonwoven fabric capable of simplifying the constitution of a production apparatus, effectively integrating a web of plural layers and controlling the release of these layers and to provide both a method and an apparatus for producing the nonwoven fabric. SOLUTION: This nonwoven fabric comprises a first layer 11 composed of recycle fiber and a second layer 12 composed of a new polyester fiber formed on the first layer. The boundary region of the layers forms a state of difference in level. The nonwoven fabric is obtained by forming one beltlike web in which the recycle fiber is divided from the new polyester fiber so as to extend in the length direction by one card apparatus, folding the web by one shaking layer and subjecting the folded web to a bonding treatment.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is used as a car floor carpet, a mat, etc.
The present invention relates to a method for producing a nonwoven fabric and a nonwoven fabric formed by laminating such that a boundary region of each layer forms a step, and an apparatus for producing a nonwoven fabric.

[0002]

2. Description of the Related Art In general, a nonwoven fabric manufacturing apparatus includes a hopper for supplying fibers, a card device for loosening and aligning the fibers supplied from the hopper to form a web, and a web device supplied from the card device. And an oscillating layer for oscillating and stacking. Below this swinging layer, a conveyor for placing and transporting the web hanging from the swinging layer is provided.

Conventionally, non-woven fabrics comprising a plurality of layers of webs are:
A plurality of card devices are arranged in the intermediate portion of the conveyor in the direction of conveyance by the conveyor, and the web formed by the next card device is sequentially laminated on the web formed by the first card device on the conveyor, It is formed by connecting the webs with a needle punch. The boundaries between the web layers forming such a nonwoven fabric are linear.

[0004]

However, according to the conventional nonwoven fabric, it is necessary to prepare a plurality of different card devices, form a web layer for each card device, and bond the webs. Was. For this reason, there has been a problem that the configuration of the entire manufacturing apparatus becomes complicated and large.
In addition, there is a problem that the bonding force between the webs made of different types of fibers is weak, and if the webs are not joined with an adhesive, they may be peeled off after long-term use.

[0005] The present invention has been made by paying attention to such problems existing in the prior art. An object of the present invention is to provide a nonwoven fabric and a nonwoven fabric manufacturing method and a nonwoven fabric manufacturing device capable of simplifying the configuration of a manufacturing apparatus, effectively integrating a plurality of layers of webs, and suppressing their separation. Is to provide.

[0006]

In order to achieve the above-mentioned object, the invention of the non-woven fabric according to claim 1 comprises laminating a web composed of different kinds of fibers, and forming layers of different kinds of fibers in upper and lower positions. It is formed so that a boundary region between the layers forms a step.

[0007] A second aspect of the present invention is the nonwoven fabric according to the first aspect, wherein a functional material is included in the fiber layer. According to the invention of the method for manufacturing a nonwoven fabric according to claim 3, a web is formed by a card device in which fibers of different types are divided so as to extend in the length direction, and the obtained web is rocked in the length direction. In addition, moving in the direction orthogonal to the swing direction, forming layers of different types of fibers on the upper and lower sides, forming a boundary region between the layers so as to form a step, and then performing a bonding process of the respective layers It is.

In the invention of the apparatus for producing a nonwoven fabric according to claim 4, a supply mechanism for supplying different kinds of fibers and a different kind of fibers supplied from the supply mechanism are divided so as to extend in the longitudinal direction. A card device for forming a web;
A swing mechanism for swinging the web formed by the card device in the length direction thereof, and a conveyor for loading the web swung by the swing mechanism and conveying the web in a direction orthogonal to the swing direction,
And a bonding mechanism for performing a bonding process of each layer on the web conveyed by the conveyor.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS (First Embodiment) A first embodiment of the present invention will be described below in detail with reference to the drawings.

As shown in FIG. 1, the nonwoven fabric is composed of a first layer 11 made of recycled fibers and a second layer 12 made of new polyester fibers formed thereon. In addition, recycled fiber is, for example, worn clothes,
By unraveling cuttings and the like of fabric products, it can be reused as fibers for raw materials.

As shown in FIG. 2, the first and second layers 11,
12 is formed by laminating a plurality of first webs 13a and second webs 13b. The first web 13a and the second web 13b are disposed adjacent to each other on the left and right, and are joined by entanglement of the respective fibers at the contact points with each other to form a single layer web 13. As shown in FIG. 5, the web 13 of a plurality of layers is formed by folding one long strip-shaped web 13 so as to have a predetermined width and laminating the web 13 vertically. Then, the nonwoven fabric is formed by bonding the webs 13 by needle punching, heat treatment, or the like. At this time, as shown in FIG. 1, the first web 13a and the first web 13b formed by the upper and lower boundaries and the left and right boundaries are formed.
The boundary region between the first and second layers 11 and 12 has a stepped shape.

As shown in FIG. 2, the first and second webs 1
On the layers 3a and 13b, granular activated carbon 14 as a functional material is contained between the webs 13 at every other layer. The activated carbon 14 allows the nonwoven fabric to exhibit functions such as deodorization. Further, the heat fusible fiber is mixed in the recycled fiber, and is melted by heating to increase the bonding force between the webs 13.

Next, a manufacturing apparatus for manufacturing the nonwoven fabric having the above configuration will be described. As shown in FIGS. 3A and 3B, the fiber supply unit 21 constituting the supply mechanism has a hopper shape, and an upper end is a fiber inlet 22 and a lower end is provided with a discharge outlet 23. The fiber supply unit 21
A first conveyor 31 is provided below the discharge port 23 of the first conveyor.

The fiber supply section 21 has a fiber input port 22 therein.
From the outlet 23 to the left and right, and two supply chambers 24
Partition walls 25 forming a and b are provided so as to extend in the traveling direction of the first conveyor 31. This partition 2
5 is configured to move left and right inside the fiber supply unit 21 and to adjust the position of each supply chamber 24 by adjusting the position.
a, 24b and the respective supply chambers 24a, 24b.
The area ratio of the outlets 23a and 23b divided for each b is changed. In the present embodiment, the partition wall 25 includes the outlet 23a of the left supply chamber 24a and the outlet 2 of the right supply chamber 24b.
The position is adjusted so that the area ratio with respect to 3b is 3: 7, and a new polyester fiber is supplied to the left supply chamber 24a and a recycled fiber is supplied to the right supply chamber 24b.

[0015] New cotton-like polyester fibers and recycled fibers supplied from the fiber input port 22 to the left and right supply chambers 24a and 24b are discharged downward from the respective discharge ports 23a and 23b. It is transported on the first conveyor 31 in an adjacent state.

The conveyor 3 is on the traveling side of the first conveyor 31.
2 are arranged, and the fibers on the first conveyor 31 are
It is conveyed to the weighing hopper 32b below the traveling side of No. 2 and discharged by a predetermined weight onto the second conveyor 33 below. Then, the paper is transferred from the second conveyor 33 to the card device 40, and is formed by the card device 40 into a single web-like web 13.

In the card device 40, a cylinder 41 is disposed on the advancing side of the second conveyor 33 via a wrap roller 42, and is supported so as to rotate in a direction indicated by an arrow in FIG. The surface has a plurality of serrated needles (not shown). Then, the fiber supplied from the second conveyor 33 is held in front of the cylinder 41 and combed into a needle on the surface of the cylinder 41.

The plurality of flats 43 are arranged along the upper peripheral edge of the cylinder 41, loosen fibers on the surface of the cylinder 41, remove dust and short fibers inside the fibers, and arrange the fibers to extend in a predetermined direction. The doffer 44 is arranged on the advancing side of the flat 43 in the rotation direction of the cylinder 41, and the fibers on the surface of the cylinder 41 are transferred by a needle provided on the surface thereof. The transferred fibers are placed in a doffer comb 44 a disposed on the advancing side of the doffer 44.
Is scraped off onto the third conveyor 35. And
The web 13 is aligned on a third conveyor 35 in a predetermined direction.
Is formed.

The above-described cylinder 41 and lap roller 4
2, the flat 43, the doffer 44, etc. to the card device 40
Is composed. As shown in FIG. 5, recycled and new polyester fibers are produced by the card device 40,
It is formed as one web 13 divided into a first web 13a and a second web 13b so as to extend in the length direction.

As shown in FIG. 3A, the card device 40
Is transported to a swing layer 50 as a swing mechanism by a third conveyor 35 composed of two conveyors having different lengths. A pair of oscillating conveyors 51 as a sending unit constituting the oscillating layer 50
Are arranged so as to face each other, and are supported by a support arm (not shown) so as to be able to swing right and left as indicated by a two-dot chain line in the figure. These swinging conveyors 51 are supported so as to have a small gap 52 to the extent that the web 13 does not slip between each other, and the web 13 is supplied into the gap 52 from above,
The web 13 is transported downward while swinging in the length direction.

As shown in FIGS. 4 (a) to 4 (c) and FIG. 6 (b), the sprayer 60 as a functional material supply mechanism is disposed at the center of the lower end of the oscillating layer 50. It is supported so as to reciprocate in the swing direction in conjunction with the moving layer 50. The sprayer 60 is provided with a hopper 61 for storing the activated carbon 14, a cylindrical quantitative spraying part 62 provided below the hopper 61, and extends obliquely downward from a lower peripheral surface of the quantitative spraying part 62. And a nozzle 63. In the fixed quantity dispersing section 62, a columnar rotating section 64 is accommodated so as to rotate about a rotating shaft 65, and a plurality of buckets 66 opening upward are attached to the peripheral surface of the rotating section 64. I have. The activated carbon 14 supplied from the hopper 61 is accommodated in the plurality of buckets 66 and is sprayed downward through the nozzle 63 by the rotation of the rotating unit 64.

A rack 67 extending in the swinging direction is provided below the swinging layer 50, and the rack 67 penetrates the peripheral surface of the fixed quantity dispersing section 62. A pinion 68 is attached to a side portion of the rotating portion 64 via a ratchet mechanism (not shown).
The rotation unit 64 rotates only in the clockwise direction with respect to 8. In addition, the pinion 68 is used for
In the rack 67. And the sprayer 60
Moves rightward in FIGS. 4A to 4C,
The rotating portion 64 is rotated clockwise in conjunction with the pinion 68, and the activated carbon 14 is sprayed. Conversely, when the sprayer 60 moves to the left, the pinion 68 rotates counterclockwise, but the rotating portion 64 does not rotate by the ratchet mechanism, and the spraying of the activated carbon 14 is stopped.

As shown in FIG. 6A, the swing layer 5
Below 0, a conveyor 34 extending in a direction orthogonal to the swing direction is provided. The web 13 placed on the conveyor 34 while being rocked by the rocking layer 50
Is transported in a direction perpendicular to the swinging direction, so that FIG.
As shown in the figure, the sheet is gradually folded while its overlapping position is slightly shifted. At this time, the activated carbon 14 is sprayed on the first and second webs 13a and 13b by the sprayer 60.

The folded web 13 is joined by a joining mechanism. As shown in FIG. 6A, in the needle punching device 70 constituting the coupling mechanism, a pair of upper and lower feed rollers 7 are provided on the traveling side of the conveyor 34.
5, a stripper plate 76b and a bed plate 76c, which are arranged vertically and a plurality of needle holes 76a are respectively provided therethrough, and a pair of upper and lower delivery rollers 77 whose rotation speed is set higher than that of the feed roller 75. It is arranged. The needle beam 71 is arranged above the stripper plate 76b so as to be able to reciprocate up and down, and a plurality of needles 72 corresponding to the needle holes 76a are hung below the needle beam 71.

The folded web 13 is transported between the stripper plate 76b and the bed plate 76c by the feed roller 75, and is extended by the delivery roller 77. In this state, the needle beam 71 moves up and down, and when the needle 72 is pierced, the fibers are entangled with each other and the webs 13 are connected.
The above-mentioned feed roller 75, stripper plate 76b,
The needle punch device 70 is constituted by the bed plate 76c, the delivery roller 77, the needle beam 71, the needle 72, and the like.

The webs 13 joined by the needle punching device 70 are heated to a predetermined temperature by a heater 74 constituting a joining mechanism, and the heat-meltable fibers in the recycled fibers are melted between the webs 13. By heat welding.

The fiber supply unit 21 and the card device 4 described above
The swinging layer 50, the sprayer 60, the conveyor 34, the coupling mechanism, and the like constitute a nonwoven fabric manufacturing apparatus.
Subsequently, a method for producing the nonwoven fabric will be described below.

When a nonwoven fabric as shown in FIG. 1 is manufactured using the manufacturing apparatus, first, as shown in FIGS. 3 (a) and 3 (b), the partition wall 25 in the fiber supply section 21 is removed. It is moved so that the area ratio of the outlets 23a, 23b of the supply chambers 24a, 24b is 3: 7. Next, a new cotton-like polyester and recycled fiber as raw materials are supplied from the fiber inlet 22 into the supply chambers 24 on the left and right sides, respectively.
a, 24b. Then, each supply chamber 24a, 2
The raw materials discharged from the respective discharge ports 23a and 23b of the base material 4b are placed on the first conveyor 31 in an adjacent state so that the discharge amount is 3: 7, are weighed to a predetermined weight, and are weighed to a second weight. From the conveyor 33, the card device 40 is left as it is.
Supplied to

Both adjacent fibers are simultaneously loosened on the surface of the cylinder 41 and transferred to the doffer 44 in a state where they are entangled at each other's boundary. Then, the new polyester fiber and the recycled fiber are intertwined with each other at the boundary, and the third conveyor 35 is provided by the doffer comb 44a.
The second web 13b and the first web 13
a is divided into webs 13 so as to extend in the longitudinal direction.
Is formed.

Next, the obtained web 13 is transferred to the swinging layer 50 by the third conveyor 35, and is then moved by the conveyor 34 in a direction perpendicular to the swinging direction while swinging in the length direction thereof. While being folded. At the same time, as shown in FIGS.
A spreader 60 is provided on the first and second webs 13a and 13b.
Activated carbon 14 is sprayed.

The sprayer 60 sprays the activated carbon 14 when moving to the right in the drawing, does not spray the activated carbon 14 when moving to the left, and the activated carbon 14 is spread every other between the webs 13. You. Then, the webs 13 are connected to each other by the needle punching device 70, and then heat-welded by the heater 74 to manufacture a nonwoven fabric.

The manufactured nonwoven fabric is cut, processed, etc., and formed, for example, as a car mat. In the nonwoven fabric thus formed as a car mat, new polyester and recycled fibers are combined at the stage of the web 13, and the first and second layers 11 and 12 are formed by laminating the web 13. ing. For this reason, even if the nonwoven fabric formed as a mat is used for a long time, peeling between the respective layers 11 and 12 can be suppressed. The nonwoven fabric can exhibit functions such as deodorization by including the activated carbon 14 therein. Further, the nonwoven fabric manufacturing apparatus is a card device 40,
Since only one swing layer 50 is provided, the size of the apparatus can be reduced as compared with the conventional manufacturing apparatus. When the webs 13 are connected to each other, it is not always necessary to perform the heat welding using the heat-meltable fibers, and the webs 13 can be sufficiently connected only by the needle punch.

The effects exerted by the first embodiment will be described below. The first and second layers 11, 1 are made by combining and laminating the nonwoven fabric with recycled and new polyester fibers at the stage of the web 13 by one card device 40.
The boundary region between the two is configured to be stepped.
Therefore, the multiple layers of the web 13 are effectively integrated,
Such peeling can be suppressed.

Since the activated carbon 14 is included in the nonwoven fabric, it is possible to impart an effect such as deodorization which is a function unique to the activated carbon 14 to the nonwoven fabric.・ Use a new polyester fiber for the surface layer of the nonwoven fabric,
Since recycled fibers are used for the other layers, they can be used for recycling and can provide a nonwoven fabric that is comparable in appearance to new ones.

Since the heat-fusible fibers are mixed into the recycled fibers forming the nonwoven fabric and the webs 13 are heat-welded, the bonding force between the webs 13 can be further increased.

The first and second webs 13a, 13b made of recycled and new polyester fibers
Is formed by forming a single web 13 sectioned so as to extend in the longitudinal direction, folding the web 13 and performing a bonding process. According to this manufacturing method, the first and second layers 11 and 12 made of recycled and new polyester fibers are effectively bonded, and
It is possible to provide a nonwoven fabric in which peeling between 1 and 12 is suppressed.

In the case where a nonwoven fabric composed of two layers of a new polyester and recycled fibers is manufactured by the manufacturing apparatus of the first embodiment, the manufacturing can be performed by one card device 40, so that the configuration of the device is simple. It can be.

Since the partition wall 25 is provided in the fiber supply unit 21 of the manufacturing apparatus, the web 13 composed of new polyester and recycled fibers can be easily formed so as to extend in the length direction. .

Since the partition wall 25 of the fiber supply section 21 is configured to be movable, the mixing ratio of new polyester and recycled fiber can be easily changed. -Since the disperser 60 for dispersing the activated carbon 14 is disposed between the swing layer 50 and the conveyor 34 of the production apparatus, the nonwoven fabric including the activated carbon 14 can be easily produced.

The sprayer 60 is configured to spray the activated carbon 14 only when the oscillating layer 50 oscillates in one direction. Therefore, the amount of the activated carbon 14 used is reduced, and the manufacturing cost is reduced. Can be achieved.

The spraying machine 60 is configured to spray the activated carbon 14 only when the web 13 supplied from the swinging layer 50 swings rightward, which is the direction covering the activated carbon 14 after being sprayed. . Activated carbon 14 after spraying
Can be prevented from scattering or spilling. (Second Embodiment) Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. The description of the second embodiment will focus on the differences from the first embodiment.

As shown in FIGS. 7 and 8A and 8B, the web 13 formed by the card device 40 is transferred by a third conveyor 35 to a swing device 80 as a swing mechanism. An apparatus body 82 is supported on a pair of support legs 81 constituting the swinging device 80, and the apparatus body 82
A conveyor 34 is provided below the table. Device body 8
A relay conveyor 83 is provided at substantially the center of the inside 2 so as to extend in the longitudinal direction of the apparatus main body 82. A supply unit 84 and a delivery unit 85 are provided above and below the relay conveyor 83, respectively.

A first roller 86 is provided in the apparatus main body 82 near the upper end of the third conveyor 35, and a second roller 86 is provided in the supply section 84.
The roller 87 is provided with a third roller 88 on the left side of the relay conveyor 83 in the drawing, and the delivery section 85 is provided with a fourth roller 89. A driven roller 90 is provided at a position near each of the rollers 86 to 89, and the first roller 8
The belt 9 is continuously connected to each of the rollers 86 to 89 and the driven roller 90 starting from the start roller 6 and ending at the fourth roller 89.
1 is mounted.

The first to fourth rollers 86 to 89, the driven roller 90 and the belt 91 constitute a transfer conveyor 92 for transferring the web 13 in the apparatus main body 82. The transfer conveyor 92 is supported so as to have a small gap between the belt 91 between the second roller 87 and the third roller 88 and the upper surface of the relay conveyor 83 such that the web 13 can pass therethrough. Similarly, the transfer conveyor 92 has a similar gap between the belt 91 between the third roller 88 and the fourth roller 89 and the lower surface of the relay conveyor 83.

The web 13 transferred from the third conveyor passes through the supply section 84 while being placed on the transfer conveyor 92, and is transferred to the delivery section 85 while being sandwiched between the transfer conveyor 92 and the relay conveyor 83. It has become so. Then, the web 13 transferred to the sending unit 85 is
The sheet is sent out by a pair of sending rollers 93 provided on the lower surface of the sending section 85, and is placed on the conveyor 34. The height of the conveyor 34 is adjustable by moving the conveyor 34 up and down. When the thickness of the web 13 to be stacked is changed, the distance from the delivery unit 85 to the conveyor 34 can be adjusted. I can do it.

The sending section 85 has a driving device (not shown), and is configured to be able to reciprocate at a constant speed in the longitudinal direction of the relay conveyor 83, that is, in the horizontal direction with respect to the apparatus main body 82, and to have a side surface thereof. One end of the chain 94a is connected. The other end of the chain 94a is the main roller 9
4b and a sub-roller 94c provided in the supply section 84, and is connected to a fixing section 94d provided at the upper right side in the apparatus main body 82 in the figure. The supply unit 84 is provided in the apparatus main body 8.
2, and is constantly urged to move leftward in the figure by an urging mechanism such as a spring, a gear, a motor, and a cylinder (not shown).

The moving mechanism 94 is constituted by the driving device, the chain 94a, the main roller 94b, the sub roller 94c, the fixing portion 94d, the urging mechanism and the like. When the sending unit 85 moves leftward in the figure by the moving mechanism 94, the supply unit 84 moves rightward against the urging force of the urging mechanism in accordance with the movement of the sending unit 85. ing. When the sending unit 85 moves rightward in the drawing, the supply unit 84 moves leftward by the urging force of the urging mechanism.

The belt 91 of the transfer conveyor 92 is an endless belt having a constant length. And
According to the moving distance of the supply unit 84 and the sending unit 85, the first
Distance between roller 86 and second roller 87 and third roller 8
The distance between the eighth roller and the fourth roller 89 changes. The supply unit 84, the moving mechanism 94, the transfer conveyor 92, and the like constitute a transfer mechanism of the web 13. With this transfer mechanism, the web 13 is transferred from the supply section 84 to the delivery section 85 at a constant speed in the apparatus main body 82.

Next, the operation of the manufacturing apparatus according to the second embodiment will be described. Now, as shown in FIG. 7, the web 13 sent from the third conveyor 35 is first placed on the transfer conveyor 92 and transferred to the supply unit 84. Next, the web 13 passes through the supply unit 84 and is transferred to the transfer conveyor 9.
2 and the sending unit 85 while being sandwiched between the relay conveyor 83.
Transported at a constant speed. On the other hand, FIGS. 8A and 8B
As shown in the figure, the sending section 85 is reciprocated at a constant speed in a horizontal direction at a lower portion of the apparatus main body 82, that is, in parallel with the surface of the conveyor 34. Then, the sending unit 85
The web 13 sent out from the inside by a pair of sending rollers 93 is folded on the conveyor 34 while swinging in the length direction.

Therefore, in the swinging device 80 of the second embodiment, the supply unit 84 and the delivery unit 85 are different from those of the first embodiment in which the swing layer 50 swings and the web 13 swings. Since the web 13 reciprocates in the horizontal direction opposite to the apparatus main body 82, the web 13 is transported in the apparatus main body 82 at a constant speed. Thereby, the web 13 is sent out onto the conveyor 34 at a constant speed, so that the web 13 can be rocked stably. In addition, when the swing width of the web 13 is increased, it is only necessary to increase the moving distance of the sending unit 85, and the adjustment can be easily performed.

The above embodiments can be embodied with the following modifications. -The functional material of each embodiment is not limited to the activated carbon 14, but may be, for example, cypress, pepper, silica gel, ceramics, bamboo charcoal, titanium oxide, or the like. Or
Liquids such as aroma oils and fragrances may be used. The included functional material is not limited to one type, but may include at least two types of different functional materials.

As described above, the forest bath effect when cypress waste is included, the heating effect for pepper, the hygroscopic effect for silica gel, the far-infrared effect for ceramics, and the aroma oil for aroma oil. An effect unique to each functional material, such as an aromatherapy effect and a relaxation effect in the case of a fragrance, can be exhibited.

When two or more types of functional materials are included, the specific effects of each functional material can be simultaneously exhibited. In each embodiment, the fibers are not limited to new polyester and recycled fibers, but may be nylon and recycled fibers, cotton and nylon, new polyester and nylon, wool and rayon, polypropylene and nylon, and the like. Or you may comprise a nonwoven fabric combining a hard layer and a soft layer.

Even in the case of such a configuration, the same effect as that of the present embodiment can be obtained, and easily peelable fibers such as polypropylene and nylon can be well bonded to each other.

For example, the partition wall 2 in the fiber supply section 21
The number of fibers constituting the nonwoven fabric may be increased by increasing the number of the partition walls 25, for example, by providing two sheets 5 and manufacturing a nonwoven fabric having a layer composed of three types of different fibers.

By simply increasing the number of the partition walls 25, a nonwoven fabric composed of layers of various kinds of fibers can be manufactured. -For example, two types of fibers are supplied from a plurality of fiber supply units 21 such that two different types of fibers are supplied by arranging two fiber supply units 21 in parallel in a direction orthogonal to the traveling direction of the first conveyor 31. May be.

In the case of such a configuration, the fiber supply unit 21
By increasing the amount of fibers stored inside, more nonwoven fabrics can be manufactured at one time. The ratchet mechanism between the rotating portion 64 and the pinion 68 may be omitted, and the activated carbon 14 may be sprayed in both directions of movement of the sprayer 60, and the activated carbon 14 may be included between the webs 13. Alternatively, the rotating unit 64 is configured to rotate counterclockwise with respect to the pinion 68, and the
When 0 moves to the left, the activated carbon 14 may be sprayed.

When the activated carbon 14 is sprayed in both directions of movement of the sprayer 60, the activated carbon 1
4, the deodorizing function can be exhibited more favorably. When the spraying machine 60 is configured to spray the activated carbon 14 when moving in the left direction, the activated carbon 14 is sprayed on the web 13 that is slightly pulled obliquely upward by the swinging layer 50. In addition, the activated carbon 14 can be prevented from scattering, spilling, etc. by being hooked on the fibers of the web 13.

The connecting mechanism may be constituted only by the needle punching device 70 without the heating device 74. When the heater 74 is omitted as described above, the manufacturing apparatus can be further simplified.

The partition wall 25 of each embodiment may be fixed inside the fiber supply section 21. With this configuration,
Different types of fibers can always be supplied at a constant mixing rate.

Further, a technical idea which can be grasped from the above embodiment will be described below. (1) The nonwoven fabric according to claim 4, wherein a functional material supply mechanism for dispersing the functional material on the web in conjunction with the swing of the swing mechanism is provided between the swing mechanism and the conveyor. manufacturing device.

With this configuration, a nonwoven fabric containing a functional material can be easily manufactured. (2) The nonwoven fabric manufacturing apparatus according to (1), wherein the functional material supply mechanism is configured to spray the functional material only when the swing mechanism swings in one direction.

With this configuration, the amount of the functional material used can be reduced, and the manufacturing cost can be reduced. (3) The nonwoven fabric manufacturing apparatus according to claim 4, wherein a partition wall is provided in the supply mechanism, and different types of fibers are supplied into each supply chamber formed by partitioning the inside of the supply mechanism.

In the case of such a configuration, the web can be easily divided. (4) The nonwoven fabric manufacturing apparatus according to (3), wherein the partition wall is configured to be movable relative to a supply mechanism.

With this configuration, the mixing ratio of different types of fibers can be easily changed. (5) The swing mechanism according to claim 4, wherein the swing mechanism has a sending unit for placing the web on a conveyor, and the sending unit includes a moving mechanism that horizontally reciprocates in a swing direction of the web. Non-woven fabric manufacturing equipment.

With this configuration, the web can be stably placed on the conveyor. (6) The moving mechanism reciprocates the sending unit at a constant horizontal speed, and the swinging mechanism further includes a transfer mechanism for transferring the web to the sending unit at a constant speed. 2. The nonwoven fabric manufacturing apparatus according to 1.).

With this configuration, the web can be more stably placed on the conveyor.

[0068]

As described above in detail, according to the present invention, the following effects can be obtained. According to the nonwoven fabric of the first aspect of the present invention, a plurality of layers of the web can be effectively integrated, and peeling thereof can be suppressed.

According to the nonwoven fabric of the second aspect,
In addition to the effects of the first aspect of the present invention, the specific effects of the functional material can be provided. According to the method for manufacturing a nonwoven fabric according to the third aspect of the present invention, it is possible to provide a nonwoven fabric in which layers made of different types of fibers are effectively bonded and peeling between the layers is suppressed.

According to the nonwoven fabric manufacturing apparatus of the fourth aspect of the present invention, the structure of the manufacturing apparatus can be simplified, the webs of a plurality of layers can be effectively integrated, and their separation can be suppressed. Non-woven fabrics can be produced.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view showing a nonwoven fabric of a first embodiment.

FIG. 2 is a conceptual diagram in which a part of a cross section of a nonwoven fabric is enlarged.

FIG. 3A is a conceptual diagram showing a state where the manufacturing apparatus is viewed from the front, and FIG. 3B is a side sectional view showing a fiber supply unit.

4 (a) is a front sectional view showing a sprayer, FIG. 4 (b) is a front sectional view showing a state where the sprayer sprays activated carbon, and FIG. 4 (c) shows a state where the sprayer stops spraying activated carbon. Front sectional view.

FIG. 5 is a perspective view showing a state in which the web is folded.

FIG. 6A is a conceptual view showing a state where the manufacturing apparatus is viewed from the side, and FIG.

FIG. 7 is a conceptual diagram showing a state in which a swing mechanism according to a second embodiment is viewed from the front.

8A is a conceptual diagram illustrating a state in which a sending unit of a swing mechanism moves, and FIG. 8B is a conceptual diagram illustrating a state in which a sending unit of the swing mechanism moves.

[Explanation of symbols]

11: first layer made of recycled fiber, 12: second layer made of new polyester fiber, 13: web, 14 ...
Activated carbon as a functional material, 21 a fiber supply unit as a supply mechanism, 34 a conveyor, 40 a card device, 50 ...
A swinging layer as a swinging mechanism; 70, a needle punch device constituting a coupling mechanism; 74, a heating machine constituting a coupling mechanism.

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Michiichi Kano 1880 Masaki, Gifu City, Gifu Prefecture Kawakawa Co., Ltd. (72) Inventor Hiroshi Nimura 47 Kitayo, Kasamatsu-cho, Hashima-gun, Gifu Prefecture F-term in Gifu Prefectural Institute of Product Technology 4F100 AA20 AA21 AA37 AD00 AJ04 AK07 AK41 AK48 AR00C BA02 BA03 BA06 BA10A BA10C BA22 DC23 DG06A DG06B EC03 EC03 EC03 EC092 GB33 JK06 JL16 4L047 AA21 BA03 CA02 CA18 CB01 CC09

Claims (4)

[Claims] 1. A nonwoven fabric in which webs made of different types of fibers are laminated, layers of different types of fibers are formed at upper and lower positions, and a boundary region between the layers forms a step. 2. The nonwoven fabric according to claim 1, wherein a functional material is contained inside the fiber layer. 3. A web which is divided by a card device so that different kinds of fibers extend in the length direction, and the obtained web is rocked in the length direction, and is orthogonal to the rocking direction. A method for producing a nonwoven fabric in which a layer made of different kinds of fibers is moved up and down to form a layer up and down, and a boundary region between the layers is formed in a stepped shape, and then the layers are bonded. 4. A supply mechanism for supplying different kinds of fibers, a card device for forming a web segmented so that different kinds of fibers supplied from the supply mechanism extend in the longitudinal direction, and a card device for forming the web. Swinging mechanism for swinging the rolled web in its length direction, a conveyor for loading the web swung by the swinging mechanism, and transporting the web in a direction orthogonal to the swinging direction, and a web transported by the conveyor And a bonding mechanism for performing a bonding process for each layer.