JP2001310343A - Nonwoven fabric and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonwoven fabric of melamine resin foam having flexibly deformable tenacity and utility like a floorcloth. SOLUTION: A plate member of melamine resin foam 1 is inserted in the gap between the upper and lower molds 2, 3 of a press processing machine and the upper and lower molds are heated to a predetermined temperature region. The upper and lower molds compress the plate member to shape the same into the nonwoven fabric 10 with a thickness (t). The compression ratio of the melamine resin foam is set to about 1/2-1/5. The plate member is reduced in its thickness by compression plastic deformation due to press compression force and heated by the upper and lower molds to lose the restoring force to the initial thickness T of the plate member. If desired, an uneven shape such as an embossed pattern or a linear pattern is formed to both of or one of the upper and lower molds to form the corresponding uneven pattern on the upper surface and/or lower surface of the nonwoven fabric.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonwoven fabric and a method for producing a nonwoven fabric, and more particularly, to a nonwoven fabric using a melamine resin foam as a raw material and a method for producing the same.

[0002]

2. Description of the Related Art Furniture such as cabinets, tables or desks, and office automation equipment
Cloth rags, disposable paper products, etc. are commonly used as cleaning tools for cleaning equipment, etc., and cleaning tools for cleaning pottery or metal tableware, bath products such as bathtubs and washbasins, etc. As such, sponges made of urethane foam resin and the like are widely used in practice. Houseworkers wipe off the object to be cleaned by dry wiping, or wipe the dirt on the object to be cleaned after impregnating the cleaning tool with water or a cleaning liquid.

In many cases, depending on the cleaning tool in a dry state, dust or the like on the surface to be cleaned can be easily wiped off, but dust such as a fine recess on the surface to be cleaned or a gap between wood fibers, or the like. It is difficult to sufficiently remove dirt or the like that has adhered stubbornly, and if the dirt is forcibly removed, abrasion or the like may be generated on the surface to be cleaned. On the other hand, in the case of a cleaning tool impregnated with an appropriate amount of water or cleaning solution,
Such dirt may be able to be removed relatively easily. However, the water or the cleaning liquid remaining on the surface to be cleaned is likely to appear on the surface to be cleaned as a wiping mark after drying, and dry wiping or the like for eliminating such wiping marks will be required again.

As a cleaning tool capable of solving such disadvantages, a cleaning tool made of a melamine-based resin foam is disclosed in Japanese Patent Laid-Open Publication No. Hei.
It is proposed in 1-128137. According to the publication, the melamine-based resin foam has a density of 5 to 50 kg /
It is made of a porous body having an open-cell structure having physical properties of m ³ , tensile strength of 0.6 to 1.6 kg / cm ² , elongation at break of 8 to 20%, and 80 to 300 cells / 25 mm. To the melamine-based resin foam, if necessary, 3 to 60 parts by weight of an anionic surfactant or a cleaning aid is added. Since the melamine-based resin foam is a relatively hard and brittle material, fine particles are separated from the cleaning tool surface by friction when rubbing the surface to be cleaned. The peeled particles are
It functions as a kind of abrasive, and exhibits a polishing action of removing dirt in the concave portion of the surface to be cleaned or removing dirt adhered stubbornly.

[0005]

Here, the area and form of the object to be cleaned are various, and the cleaning tool has a sufficient width and length, such as a cloth, a foldable deformability, and a cleaning tool. It is desirable to have flexibility or the like that can be deformed according to the form of the surface to be cleaned.

However, the melamine-based resin foam cleaning tool is a relatively fragile and hard material that is easily cracked, and has a relatively small plate (for example, tableware) having a thickness of at least about 15 to 20 mm. It has to be formed into a rectangular parallelepiped shape such as a cleaning sponge), and the melamine-based resin foam does not have toughness that can be flexibly deformed. For this reason, in a cleaning tool made of a melamine-based resin foam, it is difficult to secure the deformability of the foldable cleaning tool, the flexibility of the cleaning tool that can be deformed in accordance with the shape of the surface to be cleaned, and the like as desired. is there.

[0007] Thus, the melamine resin foam cleaning tool can be folded and stored or carried, immersed in water or a cleaning solution, then twisted or squeezed, or various objects to be cleaned according to the movement of fingers. It cannot be applied to the rag-like usability of wiping off dirt.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a melamine-based resin foam having a flexible deformable toughness and a convenience such as a cloth cloth. To provide a nonwoven fabric.

[0009]

In order to achieve the above object, the present invention provides a non-woven fabric formed by compressing and heating a melamine-based resin foam to form a sheet.

According to the above configuration of the present invention, the melamine-based resin foam molded as a relatively thick plate is compressed and heated by a press molding machine or the like, and is molded as a relatively thick sheet-like product. . The melamine-based resin foam heated at the time of compression maintains the shape to be compressed and maintains a sheet-like shape. The sheet material of the melamine-based resin foam compressed as described above constitutes a nonwoven fabric that exhibits toughness that can be flexibly deformed and has convenience such as a cloth cloth.

Thus, according to the nonwoven fabric having the above structure, it is convenient for storing or carrying, and furthermore, it can be twisted or squeezed after being immersed in water or a cleaning liquid, or can be variously cleaned in accordance with the movement of fingers. It is possible to mass-produce a cleaning tool that can be used in a cloth-like usage such as wiping off dirt on an object.

From another viewpoint, the present invention provides a nonwoven fabric laminate, wherein the nonwoven fabric having the above structure is laminated on one or both surfaces of a sheet-like substrate. From still another viewpoint, the present invention provides a method for producing a nonwoven fabric, comprising compressing a melamine-based resin foam by press working and heating to form the nonwoven fabric.

[0013]

According to a preferred embodiment of the present invention, an uneven pattern is formed on one or both surfaces of the melamine resin foam. According to another preferred embodiment of the present invention, a relatively thin sheet is laminated on one surface of the melamine-based resin foam.

In a preferred embodiment according to the production method of the present invention, the melamine-based resin foam simultaneously receives a compressing action and a heating action. In another embodiment of the present invention, the melamine-based resin foam is subjected to a heating action after being subjected to a compression action. Preferably, the compression ratio of the melamine-based resin foam is set in the range of 1/2 to 1/5. If desired, a concavo-convex pattern is formed on the melamine-based resin foam when the foam is compressed. The melamine-based resin foam is, as is known, a resin foam molded article manufactured from a melamine-formaldehyde resin obtained by a reaction of melamine and formaldehyde, and a foaming agent component, and the melamine-based resin foam itself is For example, it has already been put to practical use as a heat insulating material for buildings.

FIG. 1 is a longitudinal sectional view showing a nonwoven fabric manufacturing process according to a preferred embodiment of the present invention. As shown in FIG. 1A, a melamine-based resin foam plate 1 is inserted between an upper die 2 and a lower die 3 of a press machine. The melamine-based resin foam constituting the plate 1 has a density of 5 to 50 kg / m ^3.
(JISK6401), tensile strength 0.6-1.6 kg /
cm ² (JIS K6301), elongation at break 8-20%
(JISK6301), 80-300 cells / 25m
m (JIS K6402).

The upper die 2 and the lower die 3 constitute a die of a press machine, and include a heating element (not shown) such as an electric resistance heating wire. The heating element heats the lower and upper surfaces of the upper mold 2 and the lower mold 3 to a predetermined temperature range. The drive unit of the press machine descends the upper die 2 as shown by the arrow. The upper mold 2 and the lower mold 3 are
As shown in FIG. 1B, the plate 1 is compressed, and the plate 1 is compressed from a thickness T to a thickness t. The compression ratio t / T is 1/2
１／1/5, for example, plate thickness T = 15 mm
Is compressed to a thickness t = 5 mm.

The plate 1 is reduced in thickness by compression plastic deformation due to press compression force, and is heated by the upper mold 2 and the lower mold 3 to lose the restoring force to the initial sheet thickness T. Therefore, after the upper mold 2 returns to the initial ascending position, the nonwoven fabric 10 formed into a sheet having a thickness t is left on the lower mold 3.

If desired, an uneven shape such as an embossed pattern or a linear pattern is formed on one or both of the upper mold 2 and the lower mold 3. The concavo-convex shape formed on the lower surface of the upper mold 2 forms a corresponding concavo-convex pattern on the upper surface of the nonwoven fabric 10, and the concavo-convex shape formed on the upper surface of the lower mold 3 corresponds to the non-woven fabric 1.
0 is formed on the lower surface.

[0019]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a nonwoven fabric manufactured according to the present invention.
FIG. 2 is a perspective view illustrating a nonwoven fabric according to an example of the present invention, and FIG. 3 is a perspective view illustrating a usage pattern of the nonwoven fabric illustrated in FIG. 2.

As shown in FIG. 2, the nonwoven fabric 10 is formed into a square cloth having a plane size equivalent to a general cloth. On the upper surface of the nonwoven fabric 10, a mesh (FIG. 2A), a narrow parallel line (FIG. 2B), a wide parallel line (FIG. 2C), a large number of small circles (FIG. 2D) or a continuous needle-like pattern (FIG. 2E). Various uneven patterns 11 are formed.

As shown in FIG. 3, the user supplies water or a washing liquid to the nonwoven fabric 10 as in the case of a normal cloth, and
Round 0 and squeeze (Fig. 3A) or fold and squeeze (Fig. 3
B), the nonwoven fabric 10 having a desired wettability is used to wipe off dirt on a surface to be cleaned such as furniture. The user also cleans the soiled nonwoven fabric 10 with water, as in a normal cloth, and then stores it naturally dried.

FIG. 4 is a perspective view showing a hand cleaner type cleaning tool using the nonwoven fabric 10. As shown in FIG. The nonwoven fabric 10 is wound in a roll shape as shown in FIG.
As shown in FIG. 4 (B), the wound material 12 of FIG.
It is attached to the attachment 20 (FIG. 4D). As shown in FIG. 4 (C), the attachment 20 is composed of a pair of resin or metal holding arms 22 pivotally connected by a hinge 21 so as to be openable and closable. Detachable fitting means 23 such as a boss
Is provided. An intermediate portion of the holding arm 22 is slightly bulged outward, and a fitting means 25 such as a protrusion and a protrusion insertion boss which can be removably fitted to each other forms a pair on the inner surface of the bulged portion. Formed. A pair of circular through holes 15 through which the fitting means 25 can be inserted are formed in the center of the wound material 12. By inserting the fitting means 25 into the through hole 15 and locking the fitting means 23, the wound material 12 can be held by the attachment 20, as shown in FIG.

Attachment 20 holding roll 12
Is a resin or metal cleaning tool 30 shown in FIG.
Attached to. The cleaning tool 30 includes a holding portion 31 that can accommodate the attachment 20 and a handle 32 that extends integrally from the holding portion 31. The attachment 20 attached to the holding portion 31 slightly protrudes below the holding portion 31, and the roll 12 is exposed below the holding portion 31. The user can perform the cleaning operation by grasping the handle 32 with his fingers and applying the exposed portion of the roll 12 to the surface to be cleaned.

FIG. 5 is a sectional view and a perspective view showing another embodiment of the nonwoven fabric 10. The nonwoven fabric 10 of the present embodiment is shown in FIG.
As shown in (A), the sheet-like core material 14 is attached to both sides with an adhesive or the like. As the core material 14, a woven fabric, a nonwoven fabric, a synthetic resin sheet, a synthetic resin film, or the like can be suitably used.
As shown in FIG. 5B, an uneven pattern 11 such as an embossed pattern may be formed on the surface of the nonwoven fabric 10. In this case, different patterns can be formed on each surface of the nonwoven fabric 10.

The nonwoven fabric 10 is formed into a square cloth having a plane dimension equivalent to that of a general cloth, and is used as a dry wipe or a water wipe (FIG. 5C). As another use mode, the wound material 12 of the nonwoven fabric 10 is attached to the attachment 2
0 may be attached to the cleaning tool 30 (FIG. 6D).

FIGS. 6 and 7 are a perspective view and a sectional view showing still another embodiment of the nonwoven fabric 10. As shown in FIGS. In the embodiment shown in FIG. 6, the nonwoven fabric 10 is sewn to the back of the woven fabric 41,
The handy wiper type cleaning tool 40 is configured. Woven cloth 41
Form a bag into which fingers can be inserted. The finger of the user is inserted into the finger insertion opening 42 of the woven fabric 41, and the nonwoven fabric 10
The surface to be cleaned is moved according to the movement of the hand, and is cleaned.

In the embodiment shown in FIG. 7, the nonwoven fabric 10 is formed into a size that can be attached to the tip of a finger, and constitutes a finger-type cleaning tool 40. A band-shaped elastic body 43 such as woven cloth, rubber, or thermoplastic elastomer is attached to the nonwoven fabric 10, and an insertion opening 44 into which the tip of a finger can be inserted is formed in the nonwoven fabric 1.
0 is formed on the back surface. The user inserts the tip of the finger into the insertion slot 44. The nonwoven fabric 10 moves on the surface to be cleaned in accordance with the movement of the finger, and cleans the surface.

FIG. 8 is a perspective view and a sectional view showing a glass wiper type cleaning tool to which the nonwoven fabric 10 can be attached. In the embodiment shown in FIG. 8, the nonwoven fabric covers the tip of the cleaning tool 50. The cleaning tool 50 includes an extendable handle portion 51, and an expandable sphere 52 having a plurality of slits 53 is attached to a tip portion of the handle portion 51. As shown in FIGS. 5A and 5B, the sphere 52 deforms in accordance with the forward and backward movements of the rod 51, and expands or contracts in diameter. The nonwoven fabric 10 covers the sphere 52 as shown in FIG. The user grips the handle portion 51, applies the nonwoven fabric 10 on the sphere 52 to the surface to be cleaned, and cleans the surface to be cleaned.

FIG. 9 is a perspective view showing a handy mop type cleaning tool 60 to which the nonwoven fabric 10 can be attached. The cleaning tool 60 includes a handle portion 61 that can be gripped by fingers, a shaft member 62 having a circular cross section that can be inserted into a circular hole 64 of the handle portion 61, and a cap 63 that can be fitted to the tip of the shaft member 62. Be composed. As shown in FIG. 9A, the shaft member 62 is
The shaft member 62 has an enlarged outer peripheral surface 65 capable of supporting the same, and a sawtooth-shaped groove 66 extending substantially in the axial direction is formed at the top of the shaft member 62.

Each side edge of the nonwoven fabric 10 has an extension 17
Is formed. The extension 17 has a length substantially the same as the entire length of the groove 66. The nonwoven fabric 10 is shown in FIG.
As shown in (C), the extension portion 17 is wound around the outer peripheral surface 65, inserted into the groove 66, and held in the groove 66.

FIGS. 10 and 11 are perspective views showing another embodiment of a cleaning tool using the nonwoven fabric 10. FIG. Cleaning tools 70 and 75 for holding the rod-shaped nonwoven fabric 10 so as to be able to be fed out,
This is shown in FIG. Cleaning tool 7 shown in FIG.
0 has a slot 72 extending in the longitudinal direction, and the movable pusher 71 penetrates the slot 72. The nonwoven fabric 10 protruding slightly forward from the opening 73 extends into the cleaning tool 70 from the front end opening 73. By moving the pusher 71 forward, the nonwoven fabric 10 is pushed forward.

On the other hand, a cleaning tool 75 shown in FIG.
Includes a circular casing 76, a shaft 77 fixed to the center of the casing 76, and a rotary pusher 78 disposed in front of the shaft 77. The nonwoven fabric 10 projecting slightly forward from the opening 73 is moved from the front end opening 79 to the cleaning tool 7.
0 and goes upward along the outer periphery of the shaft portion 77. The pusher 78 has a serration on the outer peripheral surface capable of engaging with the nonwoven fabric 10, and the nonwoven fabric 10 is pushed forward from the opening 79 in accordance with the rotation of the pusher 78.

The plate-type cleaning tool 80 shown in FIG. 11 is made of an integrally molded product made of wood or resin, and has a handle portion 81 that can be gripped by a finger and a substantially rectangular enlarged support connected to the tip of the handle portion 81. And a plate 82. The nonwoven fabric 10 in the form of a flat plate
It is adhered to the upper surface of the enlarged support plate 82. The user grips the handle portion 81, applies the nonwoven fabric 10 to the surface to be cleaned, and cleans the surface to be cleaned.

FIGS. 12 and 13 are perspective views showing the nonwoven fabric 10 formed in a disk shape or a triangular shape. FIG.
The nonwoven fabric 10 shown in (A) is shaped into a disk as a whole. The circumferential edge 18 of the nonwoven fabric 10 is raised upward, and the central portion of the nonwoven fabric 10 has a form slightly depressed from the circumferential edge 18. The nonwoven fabric 10 is held by a circular cleaning tool 90 having a handle 91.

As shown in FIG. 12B, the base end of the handle 91 is connected to a ring member 92 via a hinge 96, and the ring member 92 is pivotally connected to a disk-shaped holding member 94 via a hinge 93. Be worn. The holding member 94 has substantially the same form as the nonwoven fabric 10, and the nonwoven fabric 10 is superimposed on the lower surface of the holding member 94. By pivoting the ring member 92 about the hinge 93, the non-woven fabric 10 is moved to the outer periphery 95 of the ring member 92 and the holding member 94 as shown in FIG.
Is sandwiched between. The user grips the handle 91 to apply the nonwoven fabric 10 to the surface to be cleaned, and cleans the surface to be cleaned.

The nonwoven fabric 10 shown in FIG. 13 is formed into a triangular shape as a whole. The peripheral portion 18 of the nonwoven fabric 10 protrudes upward, and the central portion of the nonwoven fabric 10 is located at a position slightly depressed from the peripheral portion 18. The nonwoven fabric 10 is held by a triangular cleaning tool 90 having a handle 91.

Both ends of the handle 91 are fixed to the holding member 94. The holding member 94 has substantially the same form as the nonwoven fabric 10, and the nonwoven fabric 10 is superimposed on the lower surface of the holding member 94. A triangular annular band plate 92 is locked to the outer peripheral edge 95 of the holding member 94 from below the nonwoven fabric 10. Non-woven fabric 10
Is sandwiched between the outer peripheral edge 95 and the band plate 94. The user grips the handle 91 to apply the nonwoven fabric 10 to the surface to be cleaned, and cleans the surface to be cleaned.

Although the preferred embodiments and examples of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments and examples, and the present invention described in the claims is not limited thereto. It goes without saying that various modifications or changes are possible within the scope.

For example, the thickness, shape, external dimensions, usage pattern, and the like of the nonwoven fabric 10 can be appropriately changed in design according to the purpose of use.

[0040]

As described above, according to the above-described structure of the present invention, it is possible to provide a melamine-based resin foam nonwoven fabric having a flexible deformable toughness and a convenience such as a cloth cloth. Becomes possible.

[Brief description of the drawings]

FIG. 1 is a vertical cross-sectional view of a pressing die showing a nonwoven fabric manufacturing process according to a preferred embodiment of the present invention.

FIG. 2 is a perspective view illustrating a nonwoven fabric according to an example of the present invention.

FIG. 3 is a perspective view illustrating a use form of the nonwoven fabric shown in FIG. 2;

FIG. 4 is a perspective view showing a handy cleaner type cleaning tool to which a nonwoven fabric can be attached.

FIG. 5 is a sectional view and a perspective view showing another embodiment of the nonwoven fabric.

FIG. 6 is a perspective view and a sectional view showing a handy wiper type cleaning tool using a nonwoven fabric.

FIG. 7 is a perspective view showing a finger-type cleaning tool using a nonwoven fabric.

FIG. 8 is a perspective view and a sectional view showing a glass wiper type cleaning tool to which a nonwoven fabric can be attached.

FIG. 9 is a perspective view showing a handy mop type cleaning tool to which a nonwoven fabric can be attached.

FIG. 10 is a perspective view showing a cleaning tool using a nonwoven fabric.

FIG. 11 is a perspective view showing another cleaning tool using a nonwoven fabric.

FIG. 12 is a perspective view showing an embodiment of a nonwoven fabric shaped into a disk.

FIG. 13 is a perspective view showing an example of a nonwoven fabric shaped in a triangular form.

[Explanation of symbols]

Reference Signs List 1 plate (melamine resin foam) 2 upper die 3 lower die 10 nonwoven fabric 20 attachment 30, 40, 50, 60, 70, 75, 80, 90 cleaning tool

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29L 7:00 B29L 7:00 F term (Reference) 4F100 AK01B AK36 AK36A AK36C AT00B BA01 BA02 BA03 BA06 BA10A BA10C BA13 DG11B DG15 DJ01A DJ01C EC182 EJ17A EJ17C EJ172 EJ42A EJ42C EJ422 GB71 HB21A HB21C JK13 JK17 4F204 AA38 AF01 AG01 AG03 AH71 FA01 FB01 FG01 FN11 FN15

Claims (9)

[Claims] 1. A non-woven fabric obtained by compressing and heating a melamine-based resin foam to form a sheet. 2. The nonwoven fabric according to claim 1, wherein an uneven pattern is formed on one or both sides of the sheet. 3. The nonwoven fabric according to claim 1, wherein a relatively thin cloth or resin sheet is laminated on one surface of the sheet. 4. A nonwoven fabric laminate comprising the nonwoven fabric according to claim 1 or 2 laminated on one or both sides of a sheet-shaped core material. 5. A method for producing a non-woven fabric, comprising compressing a melamine-based resin foam by press working and heating to form the non-woven fabric. 6. The method for producing a nonwoven fabric according to claim 5, wherein the melamine resin foam is heated while being compressed. 7. The method for producing a nonwoven fabric according to claim 5, wherein the melamine-based resin foam is heated after being compressed. 8. The melamine resin foam according to claim 5, wherein an irregular pattern is formed on the foam when the foam is compressed.
8. The method for producing a nonwoven fabric according to any one of items 1 to 7. 9. The compression ratio of the melamine-based resin foam is as follows:
5 characterized by being set in the range of 1/2 to 1/5
9. The method for producing a nonwoven fabric according to any one of items 1 to 8.