JP2008006780A - Manufacturing method of strip-like laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sheet-like laminate which is made by a simple structure and a simple manufacturing process and is used for housing articles, life articles and the like each utilizing a wooden function, and to provide its manufacturing method. <P>SOLUTION: The sheet-like laminate has the first air-permeable sheet-like layer 14, the second layer 18 laminated on the first layer 14 and made of a plurality of short cut sliced wooden pieces 16, and the third layer 20 overlying the second layer 18 and made of flexible short fibers for a non-woven fabric. The fibers of the first layer 14 and the third layer 20 get entangled with each other by a needle punch work to be integrally formed into the sheet-like body. The sliced wooden pieces 16 are thick enough for the needle 25 of the needle punch to penetrate through, and is bigger than a clearance between the fibers 12 of the first layer 14 and the fibers 13 of the third layer 20. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a sheet-like laminate that has various functions of wood and is used as a housing article, a household article, and the like, and a method for manufacturing the same.

  Conventionally, a nonwoven fabric in which fibers are used as they are can be produced quickly and in large quantities because there is no manufacturing process such as weaving or knitting like a cloth, and it is inexpensive and stable. In addition, shape workability is high, expanding the field of use. For example, Patent Document 1 discloses a sound absorbing material obtained by processing a nonwoven fabric. This includes a step of producing a functional nonwoven fabric by attaching a functional resin to the nonwoven fabric, and a step of producing a base sound-absorbing cotton fabric by laminating the cotton fabric to a predetermined thickness. This is a method for producing a sound-absorbing material in which a nonwoven fabric and a substrate sound-absorbing cotton cloth are laminated and needle punching is performed to integrate the functional nonwoven fabric and the substrate sound-absorbing cotton cloth.

Patent Documents 2 and 3 disclose a sheet-like laminate having a porous material such as charcoal, ensuring the humidity adjusting function and deodorizing function of the porous material, and having flexibility as a whole. is there. In the laminate of Patent Document 2, a porous material holding layer in which charcoal and a binder, which are porous materials, are mixed is sandwiched between two nonwoven fabrics, and a rubber layer is provided on the outer side of one nonwoven fabric. It is fixed. In the laminate of Patent Document 3, a sheet-like laminate in which charcoal is mixed is sandwiched between two foamed urethane sheets, and the outside is further sandwiched between two woven fabrics. In this sheet-like laminate, a porous material holding layer in which charcoal and a binder are mixed is sandwiched between two nonwoven fabrics and is integrally fixed by a needle punch.
Japanese Patent Laying-Open No. 2005-257709 JP 2000-343636 A JP 2000-343639 A

  The sound absorbing material disclosed in Patent Document 1 of the above prior art has a sound absorbing effect, and the sheet-like laminate disclosed in Patent Documents 2 and 3 has a humidity adjusting function and a deodorizing function. However, for example, there is no non-woven fabric having other functions such as antibacterial and insect-proofing, and there is no product combining wood and non-woven fabric. This is because it is considered that it is impossible to incorporate wood into a soft nonwoven fabric because wood is a hard and non-flexible material.

  The present invention has been made in view of the above-mentioned problems of the prior art, and with a simple structure and a simple manufacturing process, a piece of wood is formed into a sheet shape to form a housing article or a living article utilizing the function of wood. An object of the present invention is to provide a sheet-like laminate and a method for producing the same.

  The present invention provides a sheet-like first layer having air permeability, a second layer made of a plurality of sliced wood pieces that are stacked and cut short on the first layer, and a non-woven fabric layered on the second layer. A third layer made of flexible short fibers is laminated, and the first and third layers of fibers are connected by entanglement with each other by needle punching, and are integrally formed in a sheet shape. A sheet-like laminate having a thickness that can be penetrated by the needle of the needle punch and a shape larger than the gap between the fibers of the first layer and the third layer.

  Further, the first layer is formed of a non-woven fabric made of flexible fibers, and the sliced wood pieces are made of cocoons that are obtained by slicing the wood with a substantially constant thickness in the fiber direction and are cut short in a direction perpendicular to the longitudinal direction. It is what.

  According to the present invention, a sheet-like first layer having air permeability is provided, and a plurality of sliced pieces of wood cut shortly on the first layer are laminated to a predetermined thickness to form a second layer. A flexible short fiber that forms a nonwoven fabric on the layer is laminated to a predetermined thickness to form a third layer, and the first layer, the second layer, and the third layer are stacked, and needle punching is performed. This is a method for producing a sheet-like laminate in which the fibers of the first layer and the third layer are entangled and the second layer is sandwiched and formed integrally in a sheet shape.

  The first layer may be a non-woven fabric made of flexible fibers in advance. Furthermore, the third layer may be a nonwoven fabric made of flexible fibers in advance.

  The sliced wood piece is obtained by slicing wood with a substantially constant thickness in the fiber direction and cutting it at a right angle to the longitudinal direction, and with a thickness through which the needle of the needle punch can penetrate, and between the fibers of the first layer and the third layer. A shape larger than the gap is formed.

  The sheet-like laminate of the present invention and the method for producing the same securely sandwich a piece of wood in a sheet by a simple production process, taking advantage of the moisture absorption / release effect, antibacterial / insect-proofing effect, heat retention effect, etc. that are functions of wood. It can be used for household goods and household goods. Further, since the sheet-like laminate is formed by needle punching, it is easy to manufacture, and since no adhesives or chemicals containing a solvent or the like are used, the human body is not affected and is inexpensive.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1 to 3 show an embodiment of the present invention, and a sheet-like laminate 10 of this embodiment is provided with a thin nonwoven fabric first layer 14 made of flexible fibers 12. The material of the fiber 12 is, for example, a synthetic fiber such as polypropylene or polyester. On one side of the first layer 14, a second layer 18 made of slice wood pieces 16 is provided. The sliced wooden piece 16 is a thin piece of wood, and is obtained by slicing wood with a substantially constant thickness in the fiber direction and cutting it to about 1 to several centimeters in the longitudinal direction. The slice piece 16 is formed to have a thickness of, for example, about several tens of μm to several hundreds of μm. The surface of the second layer 18 opposite to the first layer 14 is appropriately set in the same manner as the fibers 12 of the first layer 14. A third layer 20 made of the non-woven fabric fibers 13 is provided. The third layer 20 is provided thicker than the first layer 14.

  In the sheet-like laminate 10, the first layer 14, the second layer 18, and the third layer 20 are compressed into a sheet shape by needle punching. Needle punching is a needle (needle) that moves up and down at high speed, repeatedly stabs the entire flat and even fiber layer, and entangles the fiber with protrusions called barbs carved into the needle. The feature of needle punching is that it is rich in bulk and does not peel between fibers. The sheet-like laminate 10 is provided with a hole 22 formed by a needle punch penetrating through and reciprocating. The fibers 12 and 13 of the first layer 14 and the third layer 20 are entangled on the inner peripheral surface of the hole 22. The second layer 18 is sandwiched and connected to each other.

  Next, an example of how to make the sheet-like laminate 10 will be described with reference to FIG. First, the fibers 12 to be the first layer 14 are leveled to a predetermined thickness to form the first layer 14. The first layer 14 may be a fiber sheet or non-woven fabric formed on a thin net in advance, or may be formed into a non-woven fabric by a subsequent needle punching process after moving to the next step with the fiber 12 layer.

  Next, the slice piece 16 to be the second layer 18 is laminated on the first layer 14 to a predetermined thickness. Then, the fibers 12 to be the third layer 20 are further laminated to a predetermined thickness on the slice piece 16 and are sent to the needle punch unit 24 by a guide roller or the like (not shown). In the needle punch portion 24, punching with the needle 25 is performed, and the fibers 12 and 13 of the first layer 14 and the third layer 20 are entangled and connected on the inner peripheral surface of the hole 22 through which the needle 25 has passed. The sliced wooden piece 16 is sandwiched to form the sheet-like laminate 10.

  The produced sheet-like laminated body 10 is wound and stored in a roll shape. The product size of the sheet-like laminated body 10 is, for example, a scroll-like body having an inner dimension of 1000 mm × 30 meters.

  Here, an example of how to make the slice piece 16 will be described with reference to FIG. First, a fixed-width plate of birch wood 26 is sliced thinly with a cannula board vertically from the back direction, that is, in the fiber direction, rather than the forehead, to form a tape-like body 26a, which is cut to an arbitrary length in the longitudinal direction. To do. The thickness of the slice wood piece 16 is set so thin that the needle 25 of the needle punch portion 24 penetrates easily. The size of the wood 26 for manufacturing the sliced wooden piece 16 is, for example, 12 mm thick, 250 mm wide, and 280 mm long, and the size of the sliced wooden piece 16 is, for example, about 12 mm wide, 13 mm long, and 150 μm thick. The sizes of the wood 26 and the slice piece 16 may be other than this.

  Moreover, you may provide the automatic stable supply machine which supplies the slice piece 16 on the fiber 12 of the 1st layer 14 automatically. This is installed on the upstream side of the needle punch portion 24 and spreads the slice piece 16 uniformly on the fiber 12 by a certain amount, and the slice piece 16 may be spread using air. The slice piece 16 can be continuously used by manually replenishing the automatic stable feeding machine.

  The method of using the sheet-like laminate 10 of this embodiment is used for various things such as house heat insulating materials, bedding, pet supplies, tatami mats, various rugs, interior decoration, footwear, and bed pads. A durable cover may be attached to the outside of the sheet-like laminate 10, or the sheet-like laminate 10 may be placed in an intermediate layer of the product.

  According to the sheet-like laminate of this embodiment and the manufacturing method thereof, the sliced wood pieces 16 can be easily formed into a sheet shape by a simple process, and can be used for various applications such as housewares and household goods. Utilizing the functions of wood, it is possible to impart functions such as moisture absorption / release properties, antibacterial / insect repellent properties, heat retention properties, heat insulation properties, sound insulation properties, and heat storage properties to products. In addition, since the scent of wood such as firewood is diffused, it has the effect of a forest bath and can stabilize mood. By using it as a living space interior and wall material, it is possible to dissipate scents and other scents in the house to create a comfortable living space. Since the 1st layer 14 and the 3rd layer 20 are made with the nonwoven fabric of the fiber 12, a space | gap is large and the volatile component and external air of the sliced wood piece 16 pass easily, and it is efficient.

  Moreover, since the fiber of the 1st layer 14 and the 3rd layer 20 is entangled in the sheet-like laminated body 10, the slice piece 16 of the 2nd layer 18 does not fall, and the sheet-like laminated body 10 is cut and processed. In this case, the sliced wood piece 16 is not spilled, so that the work for processing the product is easy. Since the sliced piece 16 is made by thinly slicing the wood 26, the sliced piece 16 is thin and flat, does not protrude outward from the gaps of the fibers 12, and does not stick into the hand, and is easy to handle. Appearance is also good.

  And in the manufacturing process of the sheet-like laminated body 10, since chemical substances, such as a solvent and an adhesive agent, are not used, an organic solvent etc. do not generate | occur | produce and it does not affect health. In addition, new uses such as domestic thinned wood can be expanded, forest resources can be used effectively, and the environment and national land can be protected.

  In addition, the sheet-like laminate of the present invention and the manufacturing method thereof are not limited to the above-described embodiment, and this use can be arbitrarily selected, such as housing articles including building materials, clothes, daily necessities, etc. It can be used for daily necessities and other appropriate applications, and the shape can be arbitrarily processed according to the application. Various materials such as natural fibers, chemical fibers, and inorganic fibers can be used as the fiber material. As the material of the sliced wood pieces, various tree species such as cedar, paulownia, hiba and pine can be used in addition to firewood, and tree species having a function suitable for the application can be appropriately selected. The thickness and size of the sliced piece of wood and the thickness of each layer can also be set as appropriate according to the application.

It is a longitudinal cross-sectional view of the sheet-like laminated body of one Embodiment of this invention. It is the schematic which shows the manufacturing method of the sheet-like laminated body of this embodiment. It is the schematic which shows the manufacturing process of the slice wooden piece of the sheet-like laminated body of this embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Sheet-like laminated body 12 Fiber 14 1st layer 16 Slice piece 18 2nd layer 20 3rd layer 22 Hole 25 Needle

Claims (6)

  A sheet-like first layer having air permeability, a second layer made of a plurality of sliced wood pieces that are stacked and cut short on the first layer, and a flexible short fiber for nonwoven fabric that is stacked on the second layer The first layer and the third layer are joined together by being entangled with each other by needle punching, and are integrally formed into a sheet shape. A sheet-like laminate having a thickness that can penetrate the needle and a shape larger than the gap between the fibers of the first layer and the third layer.   The first layer is formed of a non-woven fabric made of flexible fibers, and the slice piece is made of cocoons that are obtained by slicing the wood with a substantially constant thickness in the fiber direction and shortly cut in a direction perpendicular to the longitudinal direction. The sheet-like laminate according to claim 1.   A sheet-like first layer having air permeability is provided, a plurality of sliced pieces of wood cut shortly are laminated on the first layer to form a second layer, and a nonwoven fabric is formed on the second layer. And forming a third layer by laminating flexible short fibers forming a predetermined thickness, performing needle punching in a state where the first layer, the second layer, and the third layer are stacked, A method for producing a sheet-like laminate, wherein the fibers of the third layer are entangled, and the second layer is sandwiched and formed integrally in a sheet shape.   The method for producing a sheet-like laminate according to claim 3, wherein the first layer is a non-woven fabric made of flexible fibers in advance.   The method for producing a sheet-shaped laminate according to claim 4, wherein the third layer is a nonwoven fabric made of flexible fibers in advance. The sliced wood piece is obtained by slicing wood with a substantially constant thickness in the fiber direction and cutting it at a right angle to the longitudinal direction, and with a thickness through which the needle of the needle punch can penetrate, and between the fibers of the first layer and the third layer. The manufacturing method of the sheet-like laminated body of Claim 3 which is a shape larger than a gap | interval.

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