JP2008115505A - Collision member, apparatus and method for producing powder-containing fiber web, and powder-containing fiber web - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a collision member hardly allowing the attachment of powder, an apparatus for producing a powder-containing fiber web, which is equipped there the collision member, a method for producing the powder-containing fiber web using the apparatus, and the powder-containing fiber web produced by the apparatus. <P>SOLUTION: The collision member includes a protrusion part and a collision part body, wherein the surface of the collision part body in a region on the side ≥5 mm lower than the conversion line of the upper face and the lower face of the collision part body along the surface of the collision part body is composed of ceramic. The apparatus for producing the powder-containing fiber web has the collision member, and the method for producing the powder-containing fiber web uses the apparatus. The powder-containing fiber web is produced by the apparatus, and contains the powder uniformly dispersed therein. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a collision member that can collide with and disperse fibers and powder, a powder-containing fiber web manufacturing apparatus including the collision member, a powder-containing fiber web manufacturing method using the apparatus, and the apparatus. The present invention relates to the produced powder-containing fiber web.

  The powder-containing fiber web carrying the powder can exhibit the function of the powder in which the form of the powder is stabilized by the fiber web. For this reason, various methods have been proposed to support the powder on the fiber web. For example, after powder is sandwiched between fiber webs, the powder is physically confined between fibers using a needle punch or the like, and fixed, or after powder is sandwiched between fiber webs containing thermal bonding fibers, the powder is heated by heat treatment. There have been known a method of bonding a body and fibers and fibers, a method of pouring powder together with fibers by a wet method, and the like. However, according to the method of physically confining or adhering, the powder having a small particle size with an average particle size of 50 μm or less is likely to be detached by vibration or impact, and the particle size is relatively large so that the average particle size exceeds 50 μm. In addition, according to the squeezing method, a slurry to which a surfactant or a paste is added is used to disperse and bond fibers and powder. There has been a drawback that the activator or paste covers the surface of the powder and the original function of the powder is easily lost.

  Therefore, in order to prevent the powder from losing its original function, the applicant of the present application causes an assembly of ultrafine fibers together with the powder to be ejected from the nozzle into the gas by the action of compressed gas. We proposed a method to form a powder-containing fiber web by dividing and dispersing the body into individual ultra-short fibers, dispersing powder, and then dispersing the dispersed ultra-short fibers and powder (Patent Document) 1). It has also been proposed that an aggregate of ultrafine short fibers is ejected from a nozzle together with powder and then collided with a collision member provided in front of the nozzle injection port.

  Further, as the collision member, the applicant of the present application has a conical protrusion and a flat collision part, a flat collision member, a bell-shaped collision member, a conical collision member, and a bell-shaped protrusion. A collision member in which a portion and a flat collision portion are integrated is exemplified (Patent Document 2).

JP-A-2002-235268 (Claim 7, Claim 11, etc.) JP2003-268665A (paragraph number 0017)

  When producing a powder-containing fiber web by such a method, when collecting ultrafine short fibers and powder so that the powder with a small average particle diameter does not fall off, A fine non-woven wet cloth is placed on top, and powder and ultrafine fibers are accumulated on it, and further accumulated so that the arrangement of the powder and ultrafine fibers in the powder-containing fiber web is not disturbed. After placing the wet nonwoven fabric on the ultrafine short fibers and powder, heat treatment was performed with a dryer, etc., and the powder was fused and fixed with fibers, and then the two wet nonwoven fabrics were peeled off and fused and fixed. A powder-containing fiber web was manufactured.

  Thus, when the powder-containing fiber web fixed by fusion was manufactured, there was a case of manufacturing the powder-containing fiber web fixed by fusion having a portion where no powder exists. The inventors of the present invention have pursued the cause, and when forming the powder-containing fiber web, a part of the powder colliding with the collision member adheres to the collision member, and if the adhesion amount becomes a certain amount or more, it is a lump. Even when the heat treatment is carried out by sandwiching between two wet nonwoven fabrics, there is not a sufficient amount of fiber in the place where the powder is present as a lump, so when the wet nonwoven fabric is peeled off It was found that the lump of powder fell off.

  The powder-containing fiber web having a portion where such powder does not exist is not limited to the method of sandwiching with the wet nonwoven fabric as described above, and there is no sufficient amount of fibers even in another manufacturing method. It was caused by that.

  The present invention provides a collision member capable of solving such a problem, a powder-containing fiber web manufacturing apparatus including the collision member, a method for manufacturing a powder-containing fiber web using the apparatus, and a powder-containing fiber web manufactured by the apparatus. The purpose is to provide.

The invention according to claim 1 of the present invention is “a collision member capable of colliding with fiber and powder and dispersing them, wherein the collision member includes a protrusion and a collision portion main body, The collision member characterized in that the surface of the collision member body in the lower surface side region of 5 mm or more along the collision part body surface from the upper surface / lower surface conversion line defined below of the collision part body is made of ceramics. .
“Upper / lower surface conversion line: a line that gives an outline of the collision part main body when viewed from the axial direction of the protrusion and from the protrusion side”.

  The invention according to claim 2 of the present invention is “the impingement member according to claim 1, which is a ceramic containing 10% or more of an alumina component”.

  The invention according to claim 3 of the present invention is as follows: “A nozzle capable of ejecting fibers and powder, a compressed gas introduction means to the nozzle, and a nozzle 1 disposed in front of the nozzle outlet”. The collision member described above, an enclosure member that surrounds the collision member, guides fibers and powder dispersed by the collision with the collision member, and collects the fibers and powder guided by the enclosure member to obtain a powder A powder-containing fiber web manufacturing apparatus comprising a collecting member capable of forming a containing fiber web. "

  The invention according to claim 4 of the present invention is “a method for producing a powder-containing fiber web using the powder-containing fiber web production apparatus according to claim 3”.

  The invention according to claim 5 of the present invention is “a method for producing a powder-containing fiber web according to claim 4, wherein an inorganic powder is used as the powder”.

  The invention concerning Claim 6 of this invention is "the powder containing fiber web manufactured using the powder containing fiber web manufacturing apparatus of Claim 3."

  According to the first aspect of the present invention, the amount of powder adhering can be reduced by forming the portion of the impingement member where the powder easily adheres from ceramics. In this way, since the amount of powder attached can be reduced, it is possible to prevent the powder from falling off as a lump, and as a result, there is no part where the powder does not exist, and the powder is uniformly dispersed. The powder-containing fiber web can be manufactured.

  When the invention according to claim 2 of the present invention is a ceramic containing 10% or more of an alumina component, the amount of powder adhering to the collision member can be extremely reduced, and as a result, there is no portion where no powder exists. A powder-containing fiber web in which the powder is uniformly dispersed can be produced.

  Since the invention according to claim 3 of the present invention uses the collision member of claim 1 or claim 2, there is no portion where the powder does not exist, and the powder-containing fiber web in which the powder is uniformly dispersed. It is a device that can manufacture.

  Since the invention according to claim 4 of the present invention uses the manufacturing apparatus of claim 3, it is a method capable of producing a powder-containing fiber web in which the powder is uniformly dispersed without the presence of the powder. It is.

  The invention according to claim 5 of the present invention uses an inorganic powder as the powder. Since the inorganic powder has a similar charge train to the ceramics that make up the surface of the collision member body, the amount of inorganic powder attached can be further reduced, there is no part where the powder does not exist, and the powder is evenly dispersed. The powder-containing fiber web can be manufactured.

  Since the invention according to claim 6 of the present invention is manufactured by the manufacturing apparatus according to claim 3, it is a powder-containing fiber web in which the powder is uniformly dispersed without the presence of the powder.

  The collision member of the present invention will be described with reference to the drawings.

  FIG. 1 is a cross-sectional view of a collision member according to the present invention cut along a plane including an axis of a protrusion described later, and FIG. is there. The protrusions 1a in these drawings act to open and release the fiber supplied from the protrusion 1a side, and the upper surface of the collision part main body 1b collides with the supplied fibers and powder. It acts to spread and spread the powder and to disperse in all directions. In the collision member 1 of FIGS. 1 and 2, the protrusion 1a has a conical shape, and the collision body 1b has a bell shape with a vertical U-shaped cross section. When fibers and powder are supplied to the collision member 1 from the protruding portion 1a side and collided to disperse them, the powder adheres from the curved portion Cu to the upper surface direction of the collision portion main body 1b. 1 and 2, in the collision member 1 of FIGS. 1 and 2, the surface of the collision member main body 1b in the region on the lower surface side of 5 mm or more along the collision portion main body surface from the upper surface / lower surface conversion line Lt is made of ceramics Ce. Since it is configured, it is possible to reduce the amount of powder adhered and to prevent the powder from falling off.

  The “upper surface / lower surface conversion line” in the present invention means a line that gives an outline of the collision portion main body when viewed from the axial direction of the protruding portion and from the protruding portion side. Also, “upper surface” means the surface on the protrusion side than the upper surface / lower surface conversion line in the collision part body, and “lower surface” means the surface on the opposite side of the protrusion part from the upper surface / lower surface conversion line in the collision part body. To do.

  In the present invention, as shown in FIG. 1, in the region from the upper surface / lower surface conversion line Lt to the lower surface direction of about 5 mm, the fibers and powder flow smoothly, so that the powder adheres to the surface of the collision unit body. However, since the amount of powder tends to gradually increase on the lower surface side, it is 5 mm or more (preferably 3 mm or more, preferably) along the surface of the collision part main body 1b rather than the upper surface / lower surface conversion line Lt. The surface of the collision member main body 1b in the lower surface region is more preferably made of ceramics Ce. However, the entire surface of the collision member main body in the region on the lower surface side from the upper surface / lower surface conversion line Lt may be made of ceramics, or a part of the upper surface side from the upper surface / lower surface conversion line Lt of the collision member main body or The entire surface may be made of ceramics, and further, part or all of the surface of the protrusion 1a may be made of ceramics. Such ceramics can be formed, for example, by a thermal spraying method, a firing method, a cutting method, or the like.

  If this ceramic contains 10% or more of the alumina component (more preferably 15% or more), the amount of powder adhering to the collision member 1 can be extremely reduced, and the powder in which the powder is uniformly dispersed This is preferable because a body-containing fiber web can be produced.

  The region other than the region in which the collision unit main body surface is made of ceramics may be made of any material, and is not particularly limited, but can be made of, for example, stainless steel. In addition, the protrusion part 1a can also be comprised from ceramics and / or stainless steel.

  1 and FIG. 2, the protrusion 1a has a conical shape and the collision main body 1b has a bell shape with a U-shaped cross section. However, the present invention is not limited to this shape. For example, the protrusion has a polygonal shape such as a triangular pyramid. It can have a cone shape (see FIG. 3), a cone shape (see FIG. 4), and an outer wall surface of the cone curved in the axial direction. Polygonal columnar shape, cylindrical shape, polygonal column such as triangular prism, hemisphere (see FIG. 4), vertical cross section in the shape of an ellipse or ellipse (see FIG. 5), vertical cross section in the shape of a home base (FIG. 6) (See FIG. 7), the cross section may be a semi-elliptical or a semi-elliptical carrot.

  The powder-containing fiber web manufacturing apparatus of the present invention includes a nozzle capable of ejecting fibers and powder, a compressed gas introduction means to the nozzle, the above-described collision member disposed in front of the nozzle outlet, and the collision An enclosure member that surrounds the member and guides the fibers and powder dispersed by the collision with the collision member, and a collection that collects the fiber and powder guided by the enclosure member to form a powder-containing fiber web And a member. In this way, the above-mentioned collision member is used, and a large amount of powder adheres to the collision member and does not fall off as a lump, so a powder-containing fiber web in which the powder is uniformly dispersed is manufactured. It is a device that can.

  The powder-containing fiber web manufacturing apparatus of the present invention will be described with reference to the drawings. FIG. 8 is a schematic cross-sectional view of the fiber web manufacturing apparatus of the present invention cut along a plane perpendicular to the collecting member and parallel to the flow direction of the collecting member, and FIG. 9 is a fiber web of the present invention. It is typical sectional drawing when a manufacturing apparatus is cut | disconnected by the plane perpendicular | vertical with respect to a collection member and parallel to the width direction of a collection member. As is apparent from these drawings, the powder-containing fiber web manufacturing apparatus 10 of the present invention includes a nozzle 12, a compressed gas inlet 13, a collision member 1, an enclosure member 15, and a collection member 16.

  The nozzle 12 in FIG. 8 ejects the supplied fiber and powder from the nozzle outlet 12a to the space formed by the enclosing member 15 as described later by the action of compressed gas as described later.

  Although the nozzle 12 in FIG. 8 has a certain cross-sectional area from the compressed gas supply side (on the paper surface, the upper side) toward the nozzle outlet 12a, the nozzle in the present invention is not limited to such a nozzle, For example, it is possible to use even a nozzle whose cross-sectional area decreases continuously or discontinuously from the compressed gas supply side toward the nozzle outlet 12a. Particularly, a nozzle having a continuously increasing cross-sectional area from the compressed gas supply side toward the nozzle outlet 12a is preferable because the fibers and powder are not clogged and the fibers and powder can be uniformly dispersed. . An example of such a nozzle is a venturi tube.

  A compressed gas inlet 13 is connected to such a nozzle 12 as shown in FIG. Therefore, by introducing the compressed gas through the compressed gas introduction port 13 by the compressed gas introduction means, the fibers and powder can be supplied from the material supply port 11 to the nozzle 12 and the fibers and powder from the nozzle 12 can be supplied. The fibers are opened by the expansion force of the compressed gas when the body is ejected, and can be dispersed into individual fibers and the powder can be broken. An example of the compressed gas introducing means (not shown) is a compressor. Any gas may be used as the compressed gas, but air is suitable for manufacturing.

  Note that when the compressed gas supply to the nozzle 12 by the compressed gas introduction means is spiral, the fibers tend to be entangled with each other and the dispersibility of the fibers tends to be reduced, so the flow of the compressed gas is substantially laminar. As is the case, it is preferable to supply the compressed gas to the nozzle 12.

Moreover, it is preferable to introduce the compressed gas so that the gas passage speed at the nozzle outlet 12a is 100 m / sec or more so that the fiber opening property, dispersibility, and powder can be easily broken. For the same reason, it is preferable to introduce the compressed gas at a pressure of 2 kg / cm ² or more. Further, by providing the enclosing member 15 as will be described later, fibers and powder adhere to the inner wall of the enclosing member 15 and easily accumulate. Therefore, the inner wall of the enclosing member 15 has a shape in which airflow smoothly flows along the inner wall. It is preferable to have smoothness. If the powder-containing fiber web is manufactured for a long time, the deposit may fall off and the texture of the powder-containing fiber web may be damaged. Therefore, the gas flow rate at the collection member side end 15b of the enclosing member 15 as will be described later It is preferable to introduce a compressed gas so that is 1 m / s or more. The “gas passage speed at the nozzle outlet” is a value obtained by dividing the flow rate (m ³ / sec) of the gas jetted from the nozzle 12 by the cross-sectional area (m ² ) of the nozzle outlet 12a. The “gas flow velocity at the collecting member side end of the enclosing member” is the gas outflow amount (m ³ / sec) from the collecting member side end 15 b of the enclosing member 15. The value divided by the cross-sectional area (m ² ) of the end 15b.

  The collision member 1 as described above is disposed in front of the nozzle outlet 12a as described above. By disposing the collision member 1, it collides with fibers and powder ejected from the nozzle 12 to disperse and disperse the fibers and disperse the powder. That is, the fiber opening and the moving direction of the fiber and powder are changed by the opening by the collision with the protruding part 1a and the collision when the collision part main body 1b is reached along the surface of the protruding part 1a. Disperse the fibers and powder.

  Such a collision member 1 may be disposed in front of the nozzle outlet 12a so as to be able to collide with the ejected fibers and powders. In order to be excellent, it is preferable that the shortest distance between the connecting portion (Co in FIG. 1) between the protruding portion 1a and the collision portion main body 1b and the nozzle outlet 12a is 1 to 100 mm, preferably 5 to 40 mm. It is more preferable to install so that it is 5-30 mm, it is more preferable to install so that it is 10-30 mm, and it is still more preferable to install so that it is 10-20 mm. Most preferred. Further, in the collision member 1, the protruding portion 1a is opposed to the nozzle jet port 12a so that the fiber opening and dispersibility and the powder dispersibility are excellent, and the axis A of the protruding portion 1a is the nozzle jet port 12a. It is preferable to arrange them so as to coincide with the center of each.

  In the fiber web manufacturing apparatus 10 of the present invention, fibers and powders that surround the collision member 1 as described above and extend in the direction of the collecting member 16 as described later, and are dispersed by the collision with the collision member 1. An enclosure member 15 that guides the gas to the collection member 16 is disposed. In the present invention, the enclosure member 15 is not particularly limited as long as it can guide the fibers and powder dispersed by the collision member 1 to the collection member 16, but the collision member side end 15a is not particularly limited. If the cross-sectional shape of the material is different from the cross-sectional shape of the collecting member side end portion 15b, it is preferable because fibers and powder can be uniformly dispersed.

  8 and 9, the enclosure member 15 is used in which the cross-sectional shape at the collision member side end 15a is circular and the cross-sectional shape at the collection member side end 15b is rectangular. In such an enclosing member 15, in addition to being able to disperse fibers and powders in all directions by the collision member 1, the cross-sectional shape of the enclosing member 15 is changed from a circular shape to a rectangular shape. It is easy to make the basis weight in the direction uniform. In addition, it is not necessary to be such a surrounding member, the cross-sectional shape in the collision member side end part 15a is circular, an ellipse, or an ellipse, and the cross-sectional shape in the collection member side end part 15b is non-circular. An enclosure member can be suitably used. In particular, an enclosing member having a circular cross-sectional shape at the collision member side end 15a and a non-circular cross-sectional shape at the collection member side end 15b is preferable. More specifically, the combination of (cross-sectional shape at the collision member side end 15a) − (cross-sectional shape at the collection member side end 15b) is (circular) − (polygon), (circular) − ( (Oval), (Circular)-(Ellipse), (Ellipse)-(Polygon), (Ellipse)-(Oval), (Oval)-(Polygon), (Oval)-(Ellipse), etc. Can be mentioned.

  Such a surrounding member 15 surrounds the collision member 1, but the state is not particularly limited, and is surrounded by an appropriate distance so as not to prevent the fiber and powder from being dispersed by the collision member 1. It ’s fine. This distance can be set as appropriate by repeating the experiment. The enclosure member 15 is preferably connected to the nozzle 12 in order to prevent scattering of fibers and powder dispersed by the collision member 1.

  A collecting member 16 is provided so that the fiber and powder guided by such an enclosing member 15 can be collected to form a powder-containing fiber web. If the collecting member 16 is movable, the powder-containing fiber web can be continuously produced. The collecting member 16 is not particularly limited as long as it can collect fibers and powder, but in FIGS. 8 and 9, a net is arranged. In addition, a porous roll, a nonporous film, a nonporous roll, etc. can also be used. Among these, since the porous collection member (net, porous roll, etc.) can permeate the gas, the powder-containing fiber web can be stably formed, and the gas is sucked. By collecting fibers and powder, a powder-containing fiber web having excellent texture can be formed, which is preferable. In other words, the region with much fiber and powder on the collection member has high pressure loss, so the fiber and powder are easy to be sucked into the region with less fiber and powder and lower pressure loss. A body-containing fiber web can be formed.

  The above is the basic structure of the fiber web manufacturing apparatus 10 of the present invention. In addition to the structure described above, in order to improve the dispersibility of the fiber and powder, an apparatus for loosening the fiber and powder before the nozzle 12 ( For example, a mixer) can be installed. In addition, when the collection member 16 is porous, such as a net or a porous roll, a suction device (for example, a suction device that can suck fibers and powders to the side opposite to the collection surface of the collection member 16) It is preferable to install a suction box. 8 and 9 is an embodiment in which one enclosure member 15 is used for one nozzle 12, but an embodiment in which one enclosure member is used for two or more nozzles. good. 8 and 9 is the powder-containing fiber web manufacturing apparatus 10 including one nozzle 12 and one enclosing member 15. Two or more sets of similar nozzles and enclosing members are included in the collecting member 16. They can also be arranged in the width direction and / or in the length direction. In this case, a wide powder-containing fiber web can be produced, and the productivity of the powder-containing fiber web can be increased. Further, in FIGS. 8 and 9, the cross-sectional shape of the collecting member side end portion 15 b of the enclosing member 15 is a rectangle, and the long side direction thereof coincides with the width direction of the collecting member 16. However, even if the long side direction is aligned with the flow direction of the collecting member 16, a fiber web having excellent texture can be produced.

  Moreover, the powder-containing fiber which is more excellent in texture by providing means (moving means) capable of moving the relative position between the collecting member side end 15b of the enclosing member 15 and the collecting member 16 Webs can be manufactured. For example, the moving means may reciprocate the collecting member side end 15b of the enclosing member 15 in the flow direction and / or the width direction of the fiber web, move it in a circle or ellipse, or collect it. The member 16 can be reciprocated in the flow direction and / or the width direction of the fiber web.

  The powder-containing fiber web manufacturing method of the present invention is a manufacturing method using the powder-containing fiber web manufacturing apparatus 10 described above, and therefore there is no portion where the powder does not exist and the powder is uniformly dispersed. It is a method which can manufacture a containing fiber web.

  More specifically, first, fibers and powder are supplied to the nozzle 12, and a compressed gas is introduced into the nozzle 12 to eject the fibers and powder from the nozzle 12. The fiber supplied in the present invention is not particularly limited, but the fiber diameter is 4 μm or less and the fiber length is 3 mm or less, the ultrafine short fiber, the fiber diameter is more than 4 μm, 50 μm or less, and the fiber length is 10 mm or less. It is preferable to use thick and short fibers.

  The fiber that can be used in the production method of the present invention may be composed of any component, for example, polyamide resin, polyvinyl alcohol resin, polyvinylidene chloride resin, polyvinyl chloride resin, polyester resin, Organic components such as acrylonitrile resin, polyolefin resin (eg, polyethylene resin, polypropylene resin, etc.), polystyrene resin (eg, crystalline polystyrene, amorphous polystyrene, etc.), aromatic polyamide resin, polyurethane resin, etc. , Glass, carbon, potassium titanate, silicon carbide, silicon nitride, zinc oxide, aluminum borate, wollastonite and the like.

  Note that it is preferable that the fibers can be fused, because the powder-containing fiber web can be given strength by fusing the fibers. It is sufficient that at least a part of the components constituting the fiber surface of the fusible fiber is made of a thermoplastic resin. For example, the component constituting the fiber surface is a crystalline resin such as a polyolefin resin (for example, a polyethylene resin, a polypropylene resin, etc.), a polyvinylidene chloride resin, a polyester resin, a polyamide resin, or a crystalline polystyrene resin. What is necessary is just to be comprised from amorphous thermoplastic resins, such as a thermoplastic resin or a polyvinyl chloride resin, an amorphous polystyrene resin, a polyacrylonitrile resin, a polyvinyl alcohol resin.

  It is preferable that this fusible fiber is composed of two or more types of components because even if one type of component is fused, the fiber form can be maintained by at least one type of component. The cross-sectional shape of the fiber composed of two or more kinds of components can be, for example, a core-sheath type, an eccentric type, a sea-island type, a side-by-side type, a multiple bimetal type, an orange type, and particularly a core-sheath type The eccentric type or the sea-island type is preferable.

  Moreover, although a fiber can also be in an unstretched state, it is preferable that it is in a stretched state so that it may be excellent in strength. This “stretching” means that the film is stretched by a stretching process different from the spinning process (for example, a stretching process by a stretching yarn threading machine). For example, a fiber obtained by spraying hot air against a melt-extruded resin as in the melt blow method is not stretched because the spinning process and the stretching process are the same. In addition, the fiber manufactured by removing the sea component of the sea-island composite fiber is in a stretched state if the sea-island composite fiber is stretched.

  In addition, even if the fiber is in a bundle state in which the fibers are regularly orientated in a certain direction or in an agglomerated state in which the fibers are randomly oriented, if the apparatus 10 of the present invention is used, the fibers are opened and the powder-containing fibers have a uniform texture. Webs can be manufactured. Among these, the bundle state is preferable because it is easily dispersible by the action of a compressed gas and a collision member described later.

  Further, two or more types of fibers having different fiber diameters, fiber lengths, or components may be supplied in combination. Moreover, you may change the compounding quantity with a time-dependent change.

  The other powder can be an organic powder, an inorganic powder, a metal powder, or a composite powder of an organic substance and an inorganic substance (for example, an organic resin-coated inorganic powder), and is appropriately selected depending on the application. However, the inorganic powder is preferable because the charge train with the ceramic constituting the surface of the collision member body is close, and the amount of the inorganic powder attached can be further reduced. For example, when a powder-containing fiber web is used for ozonolysis, activated carbon or the like can be used as the powder. When a powder-containing fiber web is used for ion exchange, an ion exchange resin is used. Powders can be used, and when powder-containing fiber webs are used for catalyst applications, catalyst powders such as manganese dioxide, platinum, or titanium oxide can be used. When the web is used for deodorization or deodorization, deodorant powder, deodorant powder, etc. can be used, and the powder-containing fiber web is made of fiber reinforced plastic (FRP) or sheet-like prepreg (sheet). When used for applications such as molding compound (SMC), a heat-adhesive resin powder or the like can be used, and the powder-containing fiber web is used as a fiber for ships, bathtubs, etc. When used for applications such as reinforced plastic (overlay), thermosetting resin powder can be used, or when powder-containing fiber webs are used for fireproof boards, inorganic powder can be used. Can be used.

  In addition, as a powder, for example, heat-fusible resin powder (for example, polypropylene, polyethylene, etc.), thermosetting resin powder (for example, thermosetting polyethylene terephthalate, phenol resin), inorganic powder (for example, glass) ) And metal powder (for example, zinc, aluminum, tin, etc.), the powder can be securely fixed to the powder-containing fiber web by the adhesive action of these powders. Further, when a heat-fusible resin is included as part of the powder surface, the powder can be reliably fixed to the powder-containing fiber web by the fusion of the heat-fusible resin.

  In the powder-containing fiber web of the present invention, when the above-mentioned ultrafine short fibers are used, even a powder having an average particle diameter of 50 μm or less that has been easy to drop can be held without dropping. Since this powder is held by the fiber, the powder that can be held varies depending on the diameter of the fiber. That is, it is necessary to select a fiber having an appropriate fiber diameter according to the average particle diameter of the powder to be held. For example, Table 1 shows the relationship between the fiber diameter and the optimum average particle diameter of the powder. Even if the average particle diameter of the powder exceeds 50 μm, the powder can be held by the fibers as described above. The “average particle diameter” of the powder in the present invention refers to a value obtained by a Coulter counter method.

  The mass ratio between the fiber and the powder varies depending on the average particle diameter, specific gravity, fiber diameter, or the like of the powder. If the mass ratio of the fiber is 40 mass% or less, the average particle diameter is 50 μm or less. Even if the powder is small, it can be held so that it does not fall off, and even if it is 20 mass% or less, it is possible to produce a powder-containing fiber web in which the powder hardly falls off, and even if it is 10 mass% or less, there is no practical problem and practical handling. It is possible to produce a powder-containing fiber web that does not have any problem in strength at the time. On the other hand, if the mass ratio of the fibers is 1 mass% or more, the powder is difficult to fall off and has a practical handling strength. The higher the ratio of ultrafine short fibers having a fiber diameter of 4 μm or less and a fiber length of 3 mm or less, the better the effect. Therefore, the fiber preferably contains 20 mass% or more of ultrafine short fibers, and 50 mass. % Is more preferable, and it is most preferably composed of 100 mass% extra-fine short fibers.

Such fiber and powder are supplied to the nozzle 12 by introducing compressed gas into the nozzle 12. The compressed gas is preferably supplied to the nozzle 12 so that the flow of the compressed gas is substantially laminar so that the fibers are not easily entangled with each other. Moreover, it is preferable to introduce so that the gas passage speed in the nozzle outlet 12a is 100 m / sec or more so that the fiber opening and dispersibility and the dispersibility of the powder can be improved. For the same reason, it is preferable to introduce the compressed gas at a pressure of 2 kg / cm ² or more. Further, the compressed gas is introduced so that the gas flow velocity at the collecting member side end portion 15b of the enclosing member 15 is 1 m / s or more so that fibers and powders do not easily adhere to the inner wall of the enclosing member 15. preferable.

  In the step of ejecting the fiber and the powder, the fiber and the powder are ejected vigorously from the nozzle 12 by the action of the compressed gas. The fibers are opened and dispersed into individual fibers, and the powder is unwound by the interaction such as the expansion force of the compressed gas when ejected and the pressure difference between the inside of the nozzle 12 and the outside of the nozzle 12. .

  Next, the fibers and powder ejected from the nozzle 12 are caused to collide with the collision member 1 positioned in front of the nozzle outlet 12a to disperse the fibers and powder. That is, the ejected fiber and powder first collide with the protrusion 1a, the fiber is opened and dispersed, and the powder is unwound, and the collision part main body 1b along the surface of the protrusion 1a. To reach the connection surface with the projecting portion 1a, collide with this connection surface, the fiber is further opened, the fiber is unwound and at the same time the movement direction of the fiber and the powder is changed, in all directions scatter. In the present invention, the collision member as described above is used as the collision member 1, and the powder does not easily adhere to the collision member, so that the powder can be prevented from falling off as a lump. As described above, a powder-containing fiber web in which the powder is uniformly dispersed can be produced.

  The fibers and powder dispersed by the collision member 1 are guided to the collection member 16 by the enclosure member 15 that surrounds the collision member 1 and extends in the direction of the collection member. As described above, since the path of movement of the fibers and powder is regulated by the surrounding member 15, the fibers and powder are reliably guided to the collecting member 16.

  The fibers and powder guided by the surrounding member 15 are accumulated on the collecting member 16 to form a powder-containing fiber web. The fibers and powder may be directly accumulated on the collecting member 16, but a support (for example, fine wet nonwoven fabric) is placed on the collecting member 16 so that the powder is not easily dropped. In addition, the powder and fibers may be accumulated thereon.

  When a porous collection member 16 such as a net or a porous roll is used and gas is sucked from the surface opposite to the collection surface of the collection member 16, the powder-containing fiber web can be stably formed. In addition, a powder-containing fiber web having excellent texture can be formed. The suction force at the time of suction can be appropriately adjusted depending on the desired powder-containing fiber web, but is 1.1 times or more, preferably 1. When sucked with an air volume of 2 times or more, more preferably 1.3 times or more, a powder-containing fiber web having a better texture can be produced. In addition, although an upper limit is not specifically limited, it is economical that it is 3 times or less of the said blowing air volume.

  Moreover, a fiber web can be manufactured continuously when the collection member 16 is movable. The moving speed can be appropriately adjusted according to the desired basis weight of the powder-containing fiber web, the fibers used, the ability of the nozzle and the like. For example, when producing a high-weight powder-containing fiber web, the moving speed of the collecting member 16 is slow, and when producing a low-weighing powder-containing fiber web, the moving speed of the collecting member 16 is increased. To do.

  In addition, when collecting the fiber and the powder by the collecting member 16, if the relative position of the collecting member side end 15b of the enclosing member 15 and the collecting member 16 is moved, the powder having a better texture. A containing fiber web can be produced. As this movement, for example, reciprocation in the flow direction and / or width direction of the powder-containing fiber web at the collection member side end 15b of the enclosure member 15, circular movement or elliptical movement, or the fiber web of the collection member 16 A reciprocating motion in the flow direction and / or the width direction can be exemplified.

  Although the powder-containing fiber web produced in this way has powder attached to the fiber, it is not firmly fixed, it is easy to fall off, and the fibers are not bonded together, It is preferable to bond a powder-containing fiber web because of its low mechanical strength. Although this bonding method is not particularly limited, for example, a method of fusing fibers and / or powder, a method of bonding with a binder such as emulsion or latex, and the like may be used alone or in combination. it can. According to these methods, it is possible to obtain a bulky powder-containing fiber web. In addition, when fusing fibers and / or powder, a cover material (for example, wet nonwoven fabric) is formed on the collected fibers and powder so as not to disturb the arrangement of the powder and fibers constituting the powder-containing fiber web. ) May be carried out and then heat-treated with a dryer or the like to be fused and fixed.

  Since the powder-containing fiber web of the present invention is produced by the method as described above, the powder is uniformly dispersed and can be used in a field where various characteristics of the powder are used. . For example, an ozone decomposition sheet for an electrophotographic apparatus, a toilet deodorizer, or an ozone generator; an ion exchange sheet such as an ion exchange water purifier; a catalyst sheet such as an automobile or a chemical reaction apparatus; Deodorizing or deodorizing sheets for daily use, sanitary products, filters, shoes, etc .; fiber reinforced plastic (FRP) and sheet prepreg (SMC); or fireproof boards. The powder-containing fiber web may be subjected to various post treatments so as to suit various applications. For example, hydrophilic treatment such as charging treatment, sulfonation treatment, fluorine gas treatment, discharge treatment such as plasma treatment, water repellent treatment, and the like can be given.

  Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Preparation of extra fine fiber A)
Prepared sea island type composite short fiber (fineness: 1.7 dtex, cutting length: 1 mm) obtained by the composite spinning method, in which 25 island components consisting of high density polyethylene and polypropylene are present in the sea component composed of polylactic acid. did. This sea-island type composite short fiber is immersed in a 10 mass% sodium hydroxide aqueous solution, polylactic acid as a sea component is extracted and removed by hydrolysis, then air-dried, and ultra-fine short fiber in which high-density polyethylene and polypropylene are mixed. A bundled assembly of A (fiber diameter: 2 μm, fiber length: 1 mm, unfibrillated, stretched, cross-sectional shape: sea-island type) was obtained.

(Preparation of extra-fine short fiber B)
A sea-island type composite short fiber (fineness: 1.7 dtex, cutting length: 1 mm) obtained by a composite spinning method in which 25 island components made of polypropylene are present in a sea component made of polylactic acid was prepared. This sea-island type composite short fiber is immersed in a 10 mass% sodium hydroxide aqueous solution, and polylactic acid, which is a sea component, is extracted and removed by hydrolysis, and then air-dried to produce ultrafine short fiber B made of polypropylene (fiber diameter: 2 μm). , Fiber length: 1 mm, non-fibrillated, stretched, cross-sectional shape: circular).

(Preparation of powder A)
As the powder A, colloidal silica (gel type, average particle size: 7 μm, manufactured by Tosoh Silica Co., Ltd.) was prepared.

(Preparation of powder B)
As powder B, fumed silica (average particle diameter: 12 nm, manufactured by Nippon Aerosil Co., Ltd.) was prepared.

(Preparation of powder C)
As powder C, γ-alumina (average particle size: 10 nm, manufactured by Daimei Chemical Co., Ltd.) was prepared.

(Preparation of powder D)
As the powder D, low density polyethylene powder (average particle diameter: 6 μm, manufactured by Sumitomo Seika Co., Ltd.) was prepared.

(Preparation of collision member A)
As the collision member A, a projection part (height: 10 mm) and a collision part body (height: 30 mm) made of ceramics (alumina component: 16%) and having a shape as shown in FIG. 1 were prepared. In other words, a bell-shaped collision member A having a protruding portion 1a having a conical shape and a collision body 1b having a U-shaped cross section was prepared. The collision member A was manufactured by cutting ceramics.

(Preparation of collision member B)
As the collision member B, the protrusion (height: 10 mm) is made of stainless steel, and the area from the upper surface / lower surface conversion line Lt of the collision body (height: 30 mm) to 5 mm along the surface of the collision body is stainless steel. A region having a lower surface side of 5 mm or more along the surface of the collision part body than the upper surface / lower surface conversion line Lt is made of ceramics (alumina component: 16%) and has a shape as shown in FIG. In other words, a bell-shaped collision member B having a projecting portion 1a having a conical shape and a collision body 1b having a U-shaped cross section was prepared. In addition, the ceramic area | region of this collision part main body 1b was manufactured by cutting ceramics.

(Preparation of collision member C)
As the collision member C, the protrusion (height: 10 mm) is made of stainless steel, and the area from the upper / lower surface change line Lt of the collision body (height: 30 mm) to 20 mm along the surface of the collision body is stainless steel. A region having a lower surface side of 20 mm or more along the surface of the collision part main body from the upper surface / lower surface conversion line Lt is made of ceramics (alumina component: 16%) and has a shape as shown in FIG. In other words, a bell-shaped collision member C having a projecting portion 1a having a conical shape and a collision body 1b having a U-shaped cross section was prepared. In addition, the ceramic area | region of this collision part main body 1b was manufactured by cutting ceramics.

(Preparation of collision member D)
As the collision member D, a projection part (height: 10 mm) and a collision part body (height: 30 mm) made of stainless steel and having a shape as shown in FIG. 1 were prepared. In other words, a bell-shaped collision member D having a protruding portion 1a having a conical shape and a collision body 1b having a U-shaped cross section was prepared.

(Examples 1-8 and Comparative Examples 1-8)
A powder-containing fiber web was manufactured using a powder-containing fiber web manufacturing apparatus 10 as shown in FIGS.

That is, the ultrafine fiber mixture obtained by mixing the bundle of aggregates of ultrafine fibers A and the bundle of aggregates of ultrafine fibers B at a mass ratio of 1: 1, and powders A to D, respectively, 1 to 2. The fiber powder mixture mixed at a mass ratio of 1 is fed to the mixer to be unraveled and mixed, while being compressed from the compressor into a Venturi tube having a circular cross section at the nozzle outlet 12a (diameter: 8.5 mm). By introducing compressed air (pressure = 6 kg / cm ² , substantially laminar flow) through the gas introduction port 13, the fiber powder mixture is supplied from the material supply port 11 to the Venturi tube, and from the Venturi tube, it is extremely short. The fiber A or its aggregate, the ultra-short fiber B or its aggregate, and the powders A to D are each ejected into the air (the gas passage speed at the venturi outlet is 147 m / s, the ejection Ejection amount from:. To about 0.5 m ³ / min), and provided on the spout front of venturi tube, respectively collide with a collision member to D, ultrafine short fibers A, microfine staple fibers B and powder A -D was dispersed (the combination of the powder and the collision member is as shown in Table 1). In addition, the shortest distance between the connecting portion (Co in FIG. 1) between the protruding portion 1a and the collision portion main body 1b and the nozzle outlet 12a is 15 mm, and the axis A of the protruding portion 1a is the center of the nozzle outlet 12a. The protrusions 1a are arranged so that the vertexes of the protrusions 1a face the nozzle outlet 12a.

Next, the dispersed ultrafine fibers A, ultrafine fibers B, and powders A to D surround the collision member 1 and are connected to the Venturi tube. Wet made of polyethylene terephthalate fibers that are respectively supplied to the net (collecting member 16) and placed on the moving net by the enclosure member 15 extending linearly in the direction of the net that can accumulate A to D The powder-containing fiber web-wet nonwoven fabric assembly was obtained by accumulating on a nonwoven fabric (weight per unit area: 10 g / m ² , average fiber diameter: 3.2 μm). In addition, it is 0.7 m < ³ > / min. By the suction box arrange | positioned under the net | network. Sucked in. Further, the enclosing member 15 has a circular cross-sectional shape at the collision member side end portion 15a (inner diameter: 50 mm, cross-sectional area 19.6 cm ² ), and a cross-sectional shape at the collection member side end portion 15b is rectangular (30 mm × 60 mm, The cross-sectional area was 18 cm ² ) and the cross-sectional shape was continuously changed. Further, the distance from the nozzle outlet 12a to the collecting member side end 15b of the surrounding member 15 was 8 cm, and the air flow velocity at the collecting member side end 15b of the surrounding member 15 was 4.6 m / s. Furthermore, the collection member side end portion 15b of the surrounding member 15 is arranged so that the long side of the rectangle is parallel to the width direction of the net.

And, on the powder-containing fiber web of the powder-containing fiber web-wet nonwoven fabric assembly, a wet nonwoven fabric (weight per unit: 10 g / m ² , average fiber diameter: 3.2 μm) was further laminated. Then, it supplied to the oven set to the temperature of 130 degreeC, heat-processed for 3 minutes, it was made to melt | fuse with the high-density polyethylene component of the ultrafine short fiber A, and the powder containing fiber web-wet nonwoven fabric composite was manufactured, respectively. Thereafter, the wet nonwoven fabrics on both sides were peeled from the powder-containing fiber web-wet nonwoven fabric composite to produce fused powder-containing fiber webs. Table 1 shows the dispersion state of the powder in the fused powder-containing fiber web and the adhesion state of the powder to the impingement member when forming the powder-containing fiber web-wet nonwoven fabric assembly.

From Table 1, the powder-containing fiber web using the collision member of the present invention was excellent in quality because the powder was uniformly dispersed.

＃１：Ａ・・湾曲部、側壁のいずれにも粉体の付着がないか、わずかであるため、粉体が堆積して落下する現象は観察されず
Ｃ・・湾曲部及び／又は側壁に粉体が付着し、付着した粉体が堆積して大きな塊となって落下する現象を繰り返した
＃２：Ａ・・粉体が均一に分散しており、品位が優れている
Ｃ・・粉体の存在しない箇所が点在し、品位が悪い

# 1: A ··· There is little or no powder adhering to either the curved part or the side wall. Repeated phenomenon of powder adhering, adhering powder accumulating and falling into large lumps # 2: A. ・ Powder is uniformly dispersed and quality is excellent. The place where the body does not exist is scattered, and the quality is poor.

Sectional drawing which cut | disconnected the collision member of this invention by the plane containing the axis | shaft of a projection part A view of the collision member of the present invention viewed from the axial direction of the protrusion and from the protrusion side Sectional drawing which cut | disconnected another collision member of this invention by the plane containing the axis | shaft of a projection part Sectional drawing which cut | disconnected another collision member of this invention by the plane containing the axis | shaft of a projection part Sectional drawing which cut | disconnected another collision member of this invention by the plane containing the axis | shaft of a projection part Sectional drawing which cut | disconnected another collision member of this invention by the plane containing the axis | shaft of a projection part Sectional drawing which cut | disconnected another collision member of this invention by the plane containing the axis | shaft of a projection part Schematic sectional view when the powder-containing fiber web manufacturing apparatus of the present invention is cut along a plane perpendicular to the collecting member and parallel to the flow direction of the collecting member Schematic sectional view when the powder-containing fiber web manufacturing apparatus of the present invention is cut along a plane perpendicular to the collecting member and parallel to the width direction of the collecting member

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Collision member 1a Protrusion part 1b Collision part main body Lt Upper surface / lower surface conversion line Ce Ceramics Cu Curved part Co Connection part of a projection part and collision part main body A Projection part shaft 10 Powder-containing fiber web manufacturing apparatus 11 Material supply port 12 Nozzle 12a Nozzle outlet 13 Compressed gas inlet 15 Enclosure member 15a Collision member side end 15b Collection member side end 16 Collection member

Claims (6)

A collision member capable of colliding with fiber and powder and dispersing them, the collision member comprising a protrusion and a collision part body, and changing the upper and lower surfaces of the collision part body as defined below A collision member characterized in that the surface of the collision member main body in a region on the lower surface side of 5 mm or more along the collision section main body surface from the line is made of ceramics.
Top / bottom conversion line: A line that gives the outline of the collision part body when viewed from the axial direction of the protrusion and from the protrusion side. The impingement member according to claim 1, wherein the impingement member is a ceramic containing 10% or more of an alumina component. A nozzle capable of ejecting fibers and powder, a compressed gas introducing means to the nozzle, a collision member according to claim 1 disposed in front of the nozzle outlet, and surrounding the collision member An enclosure member that guides fibers and powder dispersed by the collision with the collision member, and a collection member that can collect the fibers and powder guided by the enclosure member to form a powder-containing fiber web. A powder-containing fiber web production apparatus. The manufacturing method of the powder containing fiber web using the powder containing fiber web manufacturing apparatus of Claim 3. The method for producing a powder-containing fiber web according to claim 4, wherein an inorganic powder is used as the powder. A powder-containing fiber web manufactured using the powder-containing fiber web manufacturing apparatus according to claim 3.

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