JP2006063492A - Nonwoven fabric with flexible bamboo fiber as material, and bedding or the like using the nonwoven fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain flexible bamboo fiber in order to utilize bamboo material as a natural resource, to provide nonwoven fabric using the flexible bamboo fiber as material, and to provide new commodities having deodorizing function, antimicrobial function, insect-controlling function, etc. as household goods, automotive internal trim materials, greening materials, etc. each using such nonwoven fabric. <P>SOLUTION: The flexible bamboo fiber is obtained by crushing a bamboo material by subjecting it to rollers to disaggregate it and by removing woody parts thereof to extract the bamboo fiber, which is maintained under pressure in a low-temperature ambience. The nonwoven fabric 9 is produced using the bamboo fiber as the material turned flexible to the extent of not being itchy on contacting with the skin. Further, such nonwoven fabric 9 is used as a padding for bedding, a seating surface for chairs or a padding for backrests, by stuffing toys or the like therewith, as an automotive internal trim material, as a material for containers, and also as a flowerpot 1a, greening tray 1b, greening mat 1c, or the like. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

The present invention relates to a non-woven fabric used as a core for a wall or ceiling of a building or structure as a sound-absorbing material, a sound-insulating material, a heat-insulating material, a non-woven fabric used as a core of a futon or a mat for a bed, a seat surface of a stool Non-woven fabric used for the core of the backrest, non-woven fabric used as an automotive interior material after secondary molding by pressing, or used as a greening material such as vegetation sheet, deodorizing function, antibacterial function , And those having an insect repellent function.
Furthermore, bedding, stools, toys, automobile interior materials, flower pots, boxes for growing grass, flowers, vegetables and the like (hereinafter simply referred to as “greening trays”), container and the above-mentioned items using such nonwoven fabric. The present invention relates to a greening mat or the like in which plant seeds and seedlings are planted on a nonwoven fabric.

Bamboo fibers were not used as a non-woven material because they tingled and hard when touched. Wall materials that are likely to be touched by human skin on a daily basis, futon and mat heartwood, stool seats and backrest, and automobile interior materials are required to be soft. This is because bad bamboo fibers were not suitable as non-woven materials.
However, since bamboo can be mass-produced and decomposed by the action of microorganisms and returned to the soil after disposal, natural materials can be used instead of synthetic fibers in order to prevent the depletion of earth resources and the destruction of the environment due to waste treatment. It is important to use bamboo as a resource.

An object of the present invention is to utilize bamboo as a natural resource in place of synthetic fiber from the viewpoints of prevention of depletion of earth resources and prevention of environmental destruction by waste treatment.
Therefore, to obtain a soft bamboo fiber softened to the extent that it does not tingle even when touched by hand, and to provide a non-woven fabric that uses soft bamboo fiber as a material and has a good touch .
Also, building materials and products that utilize bamboo fiber's deodorant function, antibacterial function, insect repellent function, etc., using wall materials and ceiling materials made of non-woven materials made of soft bamboo fibers, and using the non-woven fabrics It is to provide new building materials and products such as furniture and daily necessities, automobile interior materials made of the nonwoven fabric, and greening materials made of the nonwoven fabric.

Bamboo material is crushed with a roller and broken up, then the wood is removed and the bamboo fiber is taken out. After that, when pressure is applied in a low temperature environment and this state is maintained, the bamboo fibers become softer with time.
A non-woven fabric is manufactured using as a material bamboo fibers processed by the above-described process, which are soft enough not to tingle when touched with skin.
In addition, the non-woven fabric is packed in toys as the core of bedding, as the core of bedding, as the core of bedding, as the core of bedding, as the core of bedding, and as the interior material of automobiles And further used as materials for flowerpots, greening trays and greening mats, respectively.

Conventionally, only hard bamboo fibers can be obtained by tingling when touched by hand, but soft bamboo fibers which do not tingle even when touched by hand can be obtained by the present invention. Furthermore, it was a non-woven fabric using soft bamboo fibers, and was able to provide a non-woven fabric having a good touch.
In addition, such non-woven fabrics were used as walls and ceilings used as building materials and structural materials, pillows using the non-woven fabric as cores, futons, beds used as mat cores, and the non-woven fabrics used as cores for seating surfaces and backrests. It was possible to provide a stool, a toy using the non-woven fabric, an automobile interior material using the non-woven fabric, a container using the non-woven fabric, a flower pot using the non-woven fabric, a greening tray and a greening mat.

The invention of claim 1 is a non-woven fabric using as a material bamboo fibers that are so soft that they do not tingle when touched by the skin. Further, the invention of claim 2 uses bamboo fiber as a material which is soft enough not to tingle when touched with skin by holding bamboo fiber under pressure in a low temperature environment. Use non-woven fabric.
Bamboo is cut before and after the knots and the knots are removed. The bamboo material is crushed by a roller, and then the wood is removed to extract only the bamboo fibers. Thereafter, when the pressurized state is maintained in a low temperature environment, the bamboo fibers become softer with time.
In this way, the bamboo fiber is made soft enough not to tingle when touched by the skin, and fibers such as polypropylene, polyester, acrylic, rayon, cotton, wool, hemp, etc. are mixed appropriately to produce a nonwoven fabric. To do.
In order to achieve the purpose of using bamboo as a natural resource instead of synthetic fiber from the viewpoint of preventing the depletion of global resources and preventing environmental destruction due to waste treatment, as many bamboo fibers as possible It is preferable to use a non-woven fabric.
Invention of Claim 3 is a nonwoven fabric as described in either Claim 1 or Claim 2, Comprising: It is set as the nonwoven fabric which made the material of soft bamboo fiber and polypropylene fiber.
Since both bamboo fibers and polypropylene fibers are decomposed by the action of bacteria and returned to natural soil, the present invention can be made into a nonwoven fabric that prevents environmental destruction due to waste treatment.
The invention of claim 4 is the nonwoven fabric described in any one of claims 1 to 3, wherein the nonwoven fabric has soft bamboo fibers in a weight ratio of 20 to 100%.
In order to make a non-woven fabric having a deodorizing function, an antibacterial function, an insect repellent function, and a food freshness maintaining function obtained as a combined effect of these functions, it is necessary to mix bamboo fiber by 20% or more by weight. is there.

Invention of Claim 5 is the nonwoven fabric in any one of Claims 1-4, Comprising: By heating and compressing the fiber layer which mixed the low melting point fiber 15% or more by weight ratio, The manufactured nonwoven fabric.
Polyethylene (melting point: about 90 ° C.) is preferable as the low melting point fiber used as the binder, and polypropylene (melting point: about 160 ° C.) or polyester (melting point: about 200 ° C.) is preferable as the high melting point fiber binder.
As a method for heating the fiber layer, there are methods such as passing through a heating furnace or applying infrared rays or hot air. The heating temperature is preferably in the range of 90 to 200 ° C. The heating is performed until the binder is melted and the main raw materials such as bamboo fibers and polyester are not melted.
As a method of compressing the fiber layer, a method using a press, a method of compressing by passing between two rollers, a method of sending while compressing by a net conveyor, and the like are preferable.
Invention of Claim 6 is the nonwoven fabric in any one of Claims 1-4, Comprising: While compressing the layer of a fiber, the several needle | hook which has many pierces with respect to the layer of the said fiber is inserted / extracted Thus, a non-woven fabric manufactured by entwining fibers is obtained.
The weight ratio of bamboo fibers is high because fibers can be entangled while compressing the fibers by inserting and removing a plurality of needles having many stabs into the compressed fiber layer while compressing the fiber layer Or suitable for the production of relatively thick non-woven fabrics.
The invention according to claim 7 is the nonwoven fabric according to any one of claims 1 to 4, wherein the fiber layer is impregnated with an adhesive, and hot air is passed through the nonwoven fabric layer while compressing the nonwoven fabric. It is set as the nonwoven fabric manufactured by drying an adhesive agent.
The fiber layer is impregnated with the adhesive by spraying the adhesive on the fiber layer, dripping the adhesive or immersing the fiber layer in the liquid layer of the adhesive, and then the fiber layer. The production method of compression and drying is suitable for producing a nonwoven fabric having a relatively thin thickness when the weight ratio of bamboo fibers is large.
In order to implement this invention, it is preferable to set it as the structure which attached the hot air nozzle which blows a hot air toward the one surface of a nonwoven fabric, and attached the collection | recovery hood which attracts a hot air to the other surface side of a nonwoven fabric. This is because the hot air passes through the nonwoven fabric layer, so that the adhesive can be efficiently dried.

The invention of claim 8 is a pillow using the nonwoven fabric described in any one of claims 1 to 7 as a core, a futon, and a bed using the nonwoven fabric as a core of a mat.
The bedding using the non-woven fabric mixed with bamboo fibers in this way has a deodorizing function, antibacterial function, and insect repellent function, so it does not adhere to odor compared to conventional bedding, and does not adhere to insects or germs. It is possible to maintain this state for a long time.
When used as a core of a cushion, a futon, a mat for a bed, etc., it may be easy to bend if a cut is made in the nonwoven fabric layer in some places. Moreover, when using it for a pillow, there are a method of using it as a lump and a method of enclosing a large amount of non-woven fabric divided into small sizes, which is not particularly particular.
The invention of claim 9 is a stool using the nonwoven fabric described in any one of claims 1 to 7 as a core of a seating surface or a core of a backrest.
The non-woven fabric is enclosed as a core in a seat that is a stool such as a chair, sofa, seat, etc., on which a person puts his buttocks and keeps his weight. Further, the non-woven fabric is enclosed as a core in a backrest portion where a person entrusts his back. Furthermore, it is also preferable to use it as a core for both the seating surface and the backrest.
The stool made of non-woven fabric mixed with bamboo fibers has a deodorizing function, antibacterial function, and insect repellent function, so it has a clean state with no odor and less insects or germs. It can be maintained for a long time.
The invention of claim 10 is a stuffed toy, doll and toy made of the nonwoven fabric described in any one of claims 1 to 7 and filled with the nonwoven fabric.
Stuffed dolls, dolls and toys using non-woven fabric mixed with bamboo fibers have deodorant, antibacterial and insect repellent functions, so there is no smell compared to conventional toys, and insects and germs are attached. It is possible to maintain a clean state for a long time.
Examples of toys include dice and building toys encapsulating the non-woven fabric in them, processing the non-woven fabric itself into shapes and colors such as vegetables and fruits, and using them in mamagoto sets, shapes such as hamburgers, sandwiches and cakes and It can be processed into a color and used in a shop set, or processed into a fish shape and color and used in a fishing set.
Invention of Claim 11 makes it the motor vehicle which has the interior material of the motor vehicle which pressed and shape | molded the nonwoven fabric in any one of Claims 1-7, and the said interior material.
Automotive interior materials molded by pressing non-woven fabric mixed with bamboo fibers, and automobiles having such interior materials are conventional automobiles because the interior materials of automobiles have a deodorizing function, an antibacterial function, and an insect repellent function. It is possible to maintain a clean state for a long period of time, in which no odor is attached and no insects or germs are attached.

The invention of claim 12 provides a flowerpot and a tray for greening, wherein the nonwoven fabric described in any one of claims 1 to 7 is pressed and molded.
Flower pots and greening trays formed by pressing non-woven fabric mixed with bamboo fibers have a deodorizing function, antibacterial function, and insect repellent function, so there is no odor sticking compared to conventional flower pots and greening trays, and It is possible to maintain a clean state where no insects or germs adhere for a long time.
In addition, flowerpots and greening trays made of non-woven fabric that are decomposed by bacteria and returned to natural soil do not need to be removed from the pots when the plants grow and need to be replanted from soil to the soil. Convenient.
The invention of claim 13 is a container such as a box, a tray, or a container formed by pressing the nonwoven fabric described in any of claims 1 to 7.
Containers such as boxes, trays and containers formed by pressing non-woven fabric mixed with bamboo fibers have a deodorizing function, antibacterial function, and insect repellent function. It is possible to maintain a clean state in which insects and fungi do not adhere for a long time.
In particular, when used as a container for carrying and storing fresh food such as seafood, vegetables and fruits, it has the effect of maintaining the freshness of the fresh food for a long time.
The invention of claim 14 is the non-woven fabric according to any one of claims 1 to 7, wherein the non-woven fabric is a greening mat planted with plant seeds or seedlings.
Plants can be grown even without soil by placing a greening mat with plant seeds and seedlings on a nonwoven fabric mixed with bamboo fibers on the rooftop of a building or on a paved road surface. In addition, when used over a long period of time, it will eventually break down into bacteria and return to the soil, so it will not destroy the environment.

A method for producing soft bamboo fibers will be described as Example 1. First, the cut bamboo is cut before and after the knot to obtain a bamboo material from which the knot has been removed, and the bamboo material is crushed by a pair of rollers having a large number of protrusions. Furthermore, the wood part is removed and only bamboo fiber is taken out. Thereafter, when the pressurized state is maintained in a low temperature environment, the bamboo fibers become softer with time.
Bamboo fibers processed by the above process, which have become soft enough not to tingle when touched with the skin, are used as the nonwoven fabric material.
With regard to soft bamboo fibers, a mass production system is in place and preparations are underway to sell soft bamboo fibers, but they have not yet reached the stage of selling them as products. As soon as the mass production system is in place, soft bamboo fibers can be obtained from Foodtex Co., Ltd. (address: 3-9-10 Tarumi-cho, Suita-shi, Osaka).

Then, the structure of the nonwoven fabric manufacturing apparatus 10 which manufactures the nonwoven fabric of Example 2 concerning this invention is shown in FIG. 1, and is demonstrated.
The nonwoven fabric manufacturing apparatus 10 includes a fiber supply device 11, a heat compression molding device 12, a cutter 4, a conveying device 16, a sharing device 14, and the like.
The fiber supply device 11 is configured such that the wood 11b is attached to the belt of the belt conveyor 11a. When the fiber layer 15 is fed into the heat compression molding apparatus 12, the frictional resistance coefficient between the belt conveyor 11a and the fiber layer 15 is increased, and the fiber layer 15 is pushed in with a strong force.
The heat compression molding apparatus 12 is a net conveyor having an inclined portion 12a and a plurality of hot air nozzles 12d and configured to be vertically movable, a lower conveyor 12c being a net conveyor having a collection hood 12e, It was configured with a hot air blast recovery device that does not.
The cutter 4 is composed of a plurality of rotating disks having blades on the outer periphery thereof, and each rotating disk is attached so as to be vertically movable, and both ends of the nonwoven fabric 9 can be cut off, or the nonwoven fabric 9 can be appropriately cut to an arbitrary width. Made the configuration.
The conveying device 16 is a belt conveyor, and the belt conveyor is arranged at a distance so as not to interfere with the cutter 4 and the sharing device 14. The sharing device 14 is configured to raise and lower the blade and cut the nonwoven fabric 9 to a predetermined length.

Although the nonwoven fabric manufacturing apparatus 10 was comprised as mentioned above, hereafter, the method to manufacture the nonwoven fabric 9 of Example 2 using the nonwoven fabric manufacturing apparatus 10 is demonstrated.
The raw material fiber layer 15 is made of 50% by weight of soft bamboo fiber and 30% by weight of polyester (melting point: about 250 ° C.). As the binder, a fiber layer 15 in which 20% by weight of polyester having a melting point of about 200 ° C. was mixed was used.
The fiber layer 15 is fed into the heat compression molding apparatus 12 by the fiber supply apparatus 11, and is sandwiched between the inclined portion 12a of the upper conveyor 12b and the lower conveyor 12c and is conveyed while being gradually compressed. Since the upper conveyor 12b can be moved up and down, if it is set at a position corresponding to the thickness of the nonwoven fabric 9 to be manufactured in advance, the fiber layer is conveyed while being compressed to a desired thickness.
While the fiber layer is conveyed while being compressed by the heat compression molding apparatus 12, the fiber layer receives hot air blown from a plurality of hot air nozzles 12d. After passing through the fiber layer, the hot air is recovered by the recovery hood 12e, heated by a hot air blowing recovery device (not shown), and supplied to the hot air nozzle 12d again.
The temperature of the hot air is appropriately set within a range of 100 to 500 degrees C. In Example 2, polyester having a melting point of about 200 ° C. was used as the binder, and the feed rate was set to a high speed of about 8 m / second, so hot air of 500 ° C. was blown.
The melting point of polyester, which is the main raw material of the nonwoven fabric, is about 250 degrees C. This is because the heating temperature is a temperature at which the binder is melted, and it is sufficient that heating is performed until the fiber layer reaches about 200 ° C. as a temperature at which the main raw materials bamboo and polyester do not melt.
The nonwoven fabric 9 already molded by the heat compression molding device 12 is cut off at both ends by the cutter 4 or cut to an arbitrary width while proceeding in the traveling direction 10a, and further cut by the sharing device 14 to be long. Is wound up by a winding device, and a short one is cut into a product.

In Example 2 described above, bamboo fiber was mixed by 50% by weight and polyester including binder was mixed by 50% by weight. However, in order to prevent the depletion of global resources, bamboo material is used as a natural resource. From the viewpoints and prevention of environmental destruction due to waste treatment, it is preferable to add as much bamboo fiber as possible.
Further, from the viewpoint of exhibiting the deodorizing function, antibacterial function, insect repellent function, and the like of bamboo fibers, it is preferable to mix soft bamboo fibers by 20% or more by weight.
Furthermore, when using recycled raw materials, polypropylene, acrylic, nylon, rayon, cotton, wool, hemp and the like are mixed.
As the binder, it is also preferable to use polyethylene belonging to the low melting point fiber (melting point: about 90 ° C.), polypropylene belonging to the high melting point fiber (melting point: about 160 ° C.), or the like.
It is also possible to obtain a nonwoven fabric composed of bamboo fibers and polypropylene fibers by using polypropylene as a binder.
In addition to the method for producing the nonwoven fabric of Example 2, there is a method for producing fibers that are entangled with each other by inserting and removing a plurality of needles having a number of stabs into the fiber layer while compressing the fiber layer. is there. This manufacturing method is generally called a needle punch and does not require any particular explanation.
In the method of manufacturing the nonwoven fabric of Example 2, it is necessary to mix a binder of 15% or more by weight, but since the binder punch is not required in the manufacturing method by the needle punch, it is necessary to manufacture a nonwoven fabric with a high ratio of bamboo fibers. Is suitable.

In the nonwoven fabric of Example 3, the adhesive was sprayed on the 100% soft bamboo fiber layer, the adhesive was impregnated into the fiber layer, and the hot air was passed through the nonwoven fabric layer while being compressed. It is set as the nonwoven fabric manufactured by making it dry.
When manufacturing the nonwoven fabric of a present Example, it implements by the structure which used the nonwoven fabric manufacturing apparatus 10 shown in FIG. 1 as it is, and added the adhesive material spraying apparatus (not shown) to the upper part of the laminated fiber supply apparatus 11. FIG. The nonwoven fabric of Example 3 can be produced.
The fiber layer 15 made of bamboo fiber 100% by weight is sprayed with an adhesive material by an adhesive spraying device (not shown), and the fiber material 15 is impregnated into the fiber layer 15 by the fiber feeding device 11. It is sent to the heat compression molding apparatus 12 and is conveyed while being gradually compressed between the inclined portion 12a of the upper conveyor 12b and the lower conveyor 12c. Since the upper conveyor 12b can be moved up and down, if it is set at a position corresponding to the thickness of the nonwoven fabric 9 to be manufactured in advance, the fiber layer is conveyed while being compressed to a desired thickness.
While the fiber layer is conveyed while being compressed by the heat compression molding apparatus 12, the fiber layer receives hot air blown from a plurality of hot air nozzles 12d. After passing through the fiber layer, the hot air is recovered by the recovery hood 12e, heated by a hot air blowing recovery device (not shown), and supplied to the hot air nozzle 12d again.
The nonwoven fabric 9 already molded by the heat compression molding device 12 is cut off at the both ends by the cutter 4 or cut to an arbitrary width while proceeding in the traveling direction 10a, and further cut by the sharing device 14 to be long. Is wound up by a winding device, and a short one is cut into a product.
As described above, the nonwoven fabric of Example 3 was manufactured by impregnating the adhesive and then blowing hot air while compressing the fiber layer 15 and passing the hot air through the nonwoven fabric layer to dry the adhesive. . In this example, the temperature of the hot air was set to 250 degrees C.

Hereinafter, the greening mats 1a, 1b, and 1c of Example 4 will be described with reference to FIGS. The greening mats 1a, 1b, and 1c are each made of a nonwoven fabric 9 containing 20% or more of soft bamboo fibers by weight.
The greening mat 1a is obtained by providing a plurality of cuts 2 in the nonwoven fabric 9 at appropriate intervals in advance, and planting the seedlings 3a of the plants in the respective cuts 2 to form the greening mat 1a.
The greening mat 1b is obtained by spraying a plant seed 3b on a nonwoven fabric 9 and spraying a water-soluble resin thereon so that the plant seed 3b is covered with a water-soluble film 6.
The greening mat 1c is obtained by putting seeds and fertilizer 3c in a bag 7 made of paper, thin cloth or non-woven fabric, and attaching the bag 7 to the non-woven fabric 9 using a fastener 7a.
With the above configuration, seedlings and seeds do not fly in the wind, and if you put such a greening mat on the roof of the building, you can grow plants without soil and obtain the effect of preventing urban heat island formation Can do. The greening mat 1c is effective when used on an inclined surface.

  This invention grows bamboo and produces and sells bamboo fibers, manufactures and sells non-woven fabrics, manufactures and sells bedding, manufactures and sells furniture, and manufactures and sells toys. Industries, automobile-related industries that manufacture and sell automotive seats and interior materials, greenery-related industries that manufacture and sell flowerpots, trays for greening, and greening mats, and miscellaneous goods that manufacture and sell boxes, trays, containers, and other containers Used in related industries.

It is a front view of a nonwoven fabric manufacturing apparatus. It is a partial cross section figure of a greening mat. It is a partial cross section figure of a greening mat. It is a partial cross section figure of a greening mat.

Explanation of symbols

1a: Greening mat 1b: Greening mat 1c: Greening mat 2: Cut 3a: Plant seedling 3b: Plant seed 3c: Seed and fertilizer 4: Cutter 6: Film 7: Bag 7a: Fastener 9: Nonwoven fabric 10: Nonwoven fabric Manufacturing apparatus 10a: Traveling direction 11: Fiber feeder 11a: Belt conveyor 11b: Wood 12: Heat compression molding apparatus 12a: Inclined portion 12b: Upper conveyor 12c: Lower conveyor 12d: Hot air nozzle 12e: Collection hood 14: Sharing apparatus 15 : Fiber layer 16: Conveying device

Claims (14)

  A non-woven fabric characterized by using bamboo fibers that are soft enough not to tingle when touched by the skin.   Bamboo fiber, which is made of bamboo fiber that has been softened to the extent that it does not tingle when touched by the skin when held under pressure in a low temperature environment. Non-woven fabric.   3. A nonwoven fabric according to claim 1, wherein the material is soft bamboo fiber and polypropylene fiber.   The nonwoven fabric according to any one of claims 1 to 3, wherein the nonwoven fabric has soft bamboo fibers in a weight ratio of 20 to 100%.   The nonwoven fabric according to any one of claims 1 to 4, wherein a fiber layer in which low melting point fibers are mixed by 15% or more by weight is manufactured by heating and compressing. Non-woven fabric.   The non-woven fabric according to any one of claims 1 to 4, wherein the non-woven fabric is manufactured by inserting and removing a plurality of needles having a number of stabs into the fiber layer while compressing the fiber layer. Nonwoven fabric.   The nonwoven fabric according to any one of claims 1 to 4, wherein the fiber layer is impregnated with an adhesive, and hot air is passed through the nonwoven fabric layer while being compressed to dry the adhesive. Nonwoven fabric characterized by being manufactured.   A bed using a non-woven fabric according to any one of claims 1 to 7 as a core, a pillow, a cushion and a futon, and a bed using the non-woven fabric as a mat core.   A stool characterized by using the nonwoven fabric according to any one of claims 1 to 7 as a core of a seating surface or a core of a backrest. A stuffed toy, a doll, and a toy, characterized in that the nonwoven fabric according to any one of claims 1 to 7 is filled in or made of the nonwoven fabric.   An automobile interior material and an automobile having the interior material, wherein the nonwoven fabric according to any one of claims 1 to 7 is pressed and molded.   A flower pot and a box for growing grass, flowers, vegetables and the like, wherein the nonwoven fabric according to any one of claims 1 to 7 is pressed and molded.   A container such as a box, a tray, or a container, which is formed by pressing the nonwoven fabric according to any one of claims 1 to 7. The greening mat according to any one of claims 1 to 7, wherein plant seeds and seedlings are planted on the nonwoven fabric.

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