JP2012005982A - Manufacturing method of sheet having coating layer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a sheet which is prevented in the generation of rust at a cutting blade resulting from the adhesion of a viscous body and the deterioration of cutting performance, and has a coated layer.SOLUTION: Multiple individuated base material sheets 1A are obtained by sequentially cutting the base material sheet 1 over a direction which crosses the traveling direction of the sheet while making the base material sheet 1 formed of a continuous lengthy product travel: the coated layer is formed by coating the viscous body on one face of each individuated base material sheet 1A while making the individuated base material sheet 1A travel in a state that no gaps are formed at the front and rear of the traveling direction; and each individuated base material sheet 1B having the coated layer is made to travel by elongating a distance between the sheets 1B so that gaps may be formed at the front and rear of the traveling direction.

Description

  The present invention relates to a method for producing a sheet having a coating layer formed by coating a viscous material.

  A technique is known in which a viscous material is applied on a sheet-like base material, and then the base material is punched into a predetermined shape. For example, in Patent Document 1, a sticky exothermic composition having fluidity is patterned and laminated on a sheet-like water-absorbing sheet having air permeability, and another layer is formed so as to cover the exothermic composition from above. After laminating the water absorbent sheet, fixing the water absorbent sheet with the adhesive force of the exothermic composition sandwiched between the exothermic composition, excluding the seal portion and punching out into a shape larger than the shape of the exothermic composition A method for manufacturing a heating element is described in which the laminate is then sandwiched between a base material and a covering material, and a seal portion between the covering material and the base material is heat-sealed.

JP 2002-253593 A

  However, in the method described in Patent Document 1, punching is performed after the exothermic composition is applied on the water-absorbing sheet to form a coating layer, and therefore, at the time of punching, due to the viscosity of the exothermic composition. The exothermic composition adheres to the blade of the cutter, and manufacturing trouble is likely to occur. Also, the device is easily contaminated. Moreover, misalignment is likely to occur during punching. Furthermore, since the exothermic composition is applied in a certain pattern in the method described in the same document, when a highly viscous exothermic composition is used, the same pattern is produced with good reproducibility and productivity. It is not easy.

  Therefore, the subject of this invention is providing the manufacturing method of the sheet | seat which has a coating layer which can eliminate the fault which the prior art mentioned above has.

The present invention is a method for producing a sheet having a coating layer by applying a viscous material to a substrate sheet,
While running the base sheet composed of continuous long objects, sequentially cutting the base sheet over the direction intersecting the running direction, to obtain a plurality of individual base sheets,
Applying a viscous material to one surface of each individualized base sheet while running the individual base sheets in a state where they are arranged without a gap before and after their running direction. To form a coating layer,
Provided is a method for producing a sheet having a coating layer, in which each individual base material sheet having a coating layer is caused to travel with a distance between the sheets being widened so that a gap is formed before and after the traveling direction thereof. Is.

Further, the present invention is a method for producing a sheet having a coating layer by applying a viscous material to a substrate sheet,
While running a base sheet made of a continuous long object, the base sheet is cut in a closed shape so that a plurality of individual base sheets are formed along the running direction of the base sheet. Forming sequentially,
A base sheet made of a continuous long material with cuts formed is made of the continuous long material while running without separating the individual base material sheet from the base material sheet made of the continuous long material. Apply a viscous material on one side of the base sheet to form a coating layer,
Separating each individual base material sheet from a base material sheet composed of a continuous long material having a coating layer to obtain a plurality of individual base material sheets having a coating layer, The manufacturing method of the sheet | seat which has is provided.

Also, a method for producing a sheet having a coating layer by applying a viscous material to a base sheet,
While running a base material sheet made of a continuous long material, in order to form a plurality of individual base material sheets along the running direction of the base material sheet, in order to form a cut in the base material sheet,
A base sheet made of a continuous long material with cuts formed is made of the continuous long material while running without separating the individual base material sheet from the base material sheet made of the continuous long material. Apply a viscous material on one side of the base sheet to form a coating layer,
A part of each individual base material sheet is separated and discarded from a base material sheet made of a continuous long material having a coating layer, and it is derived from a base material sheet having a coating layer and separated and discarded. The manufacturing method of the sheet | seat which has a coating layer which obtains the several individual base material sheet | seat which has a notch part to perform is provided.

  According to the present invention, since the base material sheet is cut into a predetermined shape before the viscous material is applied to the base material sheet, the adhesion of the viscous material to the cutting blade is prevented and the adhesion of the viscous material is prevented. It is possible to prevent the cutting ability from being lowered and the occurrence of rust on the blade. As a result, stable production can be performed over a long period of time.

FIG. 1 is a schematic view showing a preferred example of a manufacturing apparatus suitably used in the method of the present invention. FIG. 2 is a diagram illustrating an example of a cutting pattern of a base material sheet made of a continuous long object. FIG. 3 is a schematic view showing another preferred example of a production apparatus suitably used in the method of the present invention. FIG. 4 is a schematic view showing still another preferred example of the production apparatus suitably used in the method of the present invention. Fig.5 (a) is a figure which shows an example of the cutting pattern formed in the base material sheet which consists of a continuous long thing, FIG.5 (b) formed the cutting pattern shown to Fig.5 (a). It is a figure which shows the state after separating and discarding the individualized base material sheet from a base material sheet. FIG. 6 is a schematic view showing still another preferred example of the production apparatus suitably used in the method of the present invention.

  The present invention will be described below based on preferred embodiments with reference to the drawings. FIG. 1 schematically shows an example of a manufacturing apparatus suitably used for carrying out the manufacturing method of the present invention. The manufacturing apparatus 10 shown in the figure includes a first cutting unit 20, a coating unit 30, a re-pitch unit 40, a sealing unit 50, and a second cutting unit 60.

  The cutting unit 20 includes a rotary die cutter 21 and an anvil roller 22. In the rotary die cutter 21, a plurality of cutting blades 21b are attached to the peripheral surface of the roller-shaped main body 21a. The cutting blade 21b is arranged such that its width direction coincides with the axial direction of the main body portion 21a, and its blade edge direction coincides with the radial direction of the main body portion 21a. The anvil roller 22 has a smooth peripheral surface. A space extending in the axial direction is formed in the anvil roller 22. This space is connected to a suction source (not shown). Furthermore, the anvil roller 22 has a large number of small holes (not shown) that open at the peripheral surface thereof and communicate with the space. When the suction source is activated, air is sucked from the peripheral surface of the anvil roller 22 toward the inside of the anvil roller 22 through the small hole. The rotary die cutter 21 and the anvil roller 22 are arranged in such a positional relationship that the cutting blade 21b of the rotary die cutter 21 and the peripheral surface of the anvil roller 22 come into contact with each other or a predetermined clearance is generated therebetween.

  The coating unit 30 has a die coater 31. The coating unit 30 also includes a breathable endless belt 32 made of wire mesh that faces the die lip of the die coater 31 and circulates in the direction of the arrow. Furthermore, a suction box 33 is also provided opposite to the die lip of the die coater 31 with the endless belt 32 interposed therebetween.

  Furthermore, the coating part 30 also has the coating layer dividing means 36 of the base material sheet which was individualized and the coating layer was formed. The coating layer dividing means 36 may be, for example, a cylindrical member made of wire or a blade made of polytetrafluoroethylene. By performing the cutting process of the coating layer by the coating layer dividing means 36, the coating layer continuously formed by the continuous coating of the coating liquid can be successfully separated.

  The re-pitch portion 40 includes an endless belt 43. The circumferential speed of the endless belt 43 is set to be higher than the circumferential speed of the endless belt 32 provided in the coating unit 30. Due to this speed difference, the pitch between the individual base material sheets 1B continuously conveyed is changed. In addition, as the pitch changing device, a known device that can change the pitch of a plurality of individual articles continuously conveyed can be used without any particular limitation. Details of such an apparatus are described in, for example, EP0812789 and JP-T-2004-504107. In addition, the re-pitch portion 40 also includes a merging portion 41 of the first covering sheet and a merging portion 42 of the second covering sheet.

  The sealing portion 50 includes a seal roller 51 having a seal convex portion 51a and a seal roller 52 having a seal convex portion 52a. The seal roller 51 and the seal roller 52 can be heated to a predetermined temperature. The seal roller 51 and the seal roller 52 are arranged in a positional relationship such that the seal convex portion 51a of the seal roller 51 and the seal convex portion 52a of the seal roller 52 come into contact with each other or a predetermined clearance is generated therebetween.

  The second cutting unit 60 includes a rotary die cutter 61 and an anvil roller 62. The rotary die cutter 61 and the anvil roller 62 are arranged in such a positional relationship that the cutting blade 61b of the rotary die cutter 61 and the peripheral surface of the anvil roller 62 come into contact with each other or a predetermined clearance is generated therebetween.

  If the manufacturing method of the sheet | seat which has the coating layer which has the above structure is demonstrated, the base material sheet 1 will be unreeled from the raw fabric roll which is not shown in figure, and will drive | work in the form of a continuous long thing. And the base material sheet 1 is introduce | transduced into the 1st cutting part 20, is cut | disconnected sequentially over the direction which cross | intersects a running direction, and becomes the individual base material sheet 1A of each leaf. When cutting the continuous long base material sheet 1, a suction source (not shown) connected to the anvil roller 22 in the first cutting part 20 is operated to perform suction by the anvil roller 22. Even if the continuous long base material sheet 1 is cut by this suction and becomes the individual base material sheet 1A, the base material sheet 1A is sucked to the peripheral surface of the anvil roller 22. Therefore, each base sheet 1A is maintained in a state where it is arranged without providing a gap before and after those traveling directions, and travels in that state.

  The base material sheet 1 made of a continuous long material may be cut so as to extend in the width direction of the base material sheet 1. For example, the base material sheet 1 can be linearly formed across the width direction of the base material sheet 1. Alternatively, as shown in FIG. 2, cutting can be performed so that the cutting line C draws a curve. In any case, it is preferable to employ a cutting pattern that does not cause trimming by cutting.

  The individual base sheet 1 </ b> A that has been individualized is introduced from the first cutting unit 20 to the coating unit 30, and is transferred to an endless belt 32 provided in the coating unit 30. The endless belt 32 is air permeable, and the suction box 33 disposed at a position facing the base sheet 1A across the endless belt 32 is operated, and the conveyance speed is the same as that of the anvil roller 22. Thus, the transfer of the base sheet 1A to the endless belt 32 is performed smoothly. Accordingly, even after the transfer to the endless belt 32, each base sheet 1A travels while being maintained without being provided with a gap before and after those travel directions.

  In the coating part 30, the coating liquid of a viscous body is apply | coated to the surface of each base material sheet 1A. A viscous material is a kind of fluid, and generally refers to fluid materials such as paint, gel, slurry, cream, ink, and dough. The coating liquid may be applied to the entire surface of the base sheet 1A, or may be applied so that the side area in the running direction of the base sheet 1A is a non-coating area. Moreover, you may apply | coat a coating liquid so that the strip | belt-shaped coating area along the running direction of 1 A of base materials may be formed in stripe form. At the time of application of the coating liquid, each base sheet 1A is not provided with a gap with the other base sheet 1A adjacent to the front and rear in the running direction, so the coating liquid is continuously applied. However, the apparatus 10 including the endless belt 32 is not soiled with the coating liquid. That is, the viscous coating liquid is continuously applied to the base sheet 1A.

Among the various viscous materials described above, when the viscous material is, for example, a slurry in which powder is dispersed in a liquid medium, the viscosity of the slurry is 500 to 20,000 mPa · s, particularly 1,000 to 10%. 1,000 mPa · s is preferable. The viscosity is measured using, for example, a No. 4 rotor of a B-type viscometer in an environment of 23 ° C. and 50% RH.
Measuring instrument: BII type viscosity type BHII No. manufactured by Toki Sangyo Co., Ltd. 4 rotors
Rotation speed 6 ~ 20rpm
Further, when the viscous material is, for example, dough, the viscosity of the dough is preferably 3,000 to 300,000 mPa · s at a shear rate of 10 s ⁻¹ , and 60 to 20,000 at a shear rate of 1000 s ⁻¹ . 000 mPa · s is preferable. A dough is a kneaded product of a powder composition and a fluid substance such as a liquid, paste, or gel, as described in, for example, Japanese Patent Application Laid-Open No. 10-204499 related to the previous application of the present applicant. Say. The material having fluidity includes those that are fluidized by heating, pressurizing, or shearing. The viscosity of the dough is measured using, for example, the following measuring device in an environment of 23 ° C. and 50% RH.
Measuring instrument: HAAKE, rotational viscosity type Rotovisco RV20
A test fixture (inner diameter 19.2 mm, outer diameter 23.1 mm, gap 1.9 mm, inner cylinder length 31.95 mm) is used.
Furthermore, when the viscous material is, for example, a gel (for example, a hydrous gel used for a cosmetic sheet or the like), the viscosity of the gel is preferably 400,000 to 1,300,000 mPa · s. The viscosity is measured using, for example, the following measuring instrument in an environment of 23 ° C. and 50% RH.
Measuring device: Toki Sangyo Co., Ltd. rotational viscometer TV-10R type T-bar stage TS-10 type T-bar spindle Rotating speed 5 rpm Measuring time 1 minute Stage rising speed 20 mm / min

  In applying the coating liquid, suction is performed by a suction box 33 installed at a position facing the die coater 31. Therefore, when the base sheet 1A has air permeability, for example, when the base sheet 1A is a fiber sheet, the coating liquid can be stably applied to the base sheet 1A by the above suction. A construction layer can be formed.

  Thus, the coating liquid which consists of a viscous body is applied to one surface of 1 A of base material sheets, and a coating layer is formed. In the following description, each base material sheet 1A on which a coating layer is formed is referred to as a coating sheet 1B. Each coating sheet 1 </ b> B travels without being provided with a gap between the other coating sheets 1 </ b> B adjacent in the traveling direction, and is introduced into the re-pitch portion 40. Using the re-pitch portion 40, the distance between the coating sheets 1B is widened so that a gap is formed before and after the traveling direction of each coating sheet 1B. This distance can be arbitrarily determined according to the setting of the re-pitch device.

  Before extending the distance between the coating sheets 1B, the coating layer dividing means 36 reliably separates the coating layers between the individual coating sheets 1B, and performs the re-pitch in the re-pitch portion 40 successfully. It is preferable to obtain. By doing so, it is possible to effectively prevent stringing of the viscous coating liquid during re-pitching. When applying a coating solution that does not cause stringing, the coating layer dividing means 36 does not need to be provided.

  In the re-pitch portion 40, the distance between the coating sheets 1B adjacent to each other in the front and rear directions is increased, and a first continuous long object is formed on the upper surface side of each coating sheet 1B, that is, on the side on which the coating layer is formed. The 2nd covering sheet 3 which consists of a continuous long thing similarly is arrange | positioned on the lower surface side. Thus, the laminated body 4 with which the 2nd coating sheet 3, the coating sheet 1B, and the 1st coating sheet 2 were piled up is formed. This laminated body 4 consists of a continuous long thing by which the coating sheet 1B was intermittently arrange | positioned.

  It is preferable that the first and second cover sheets 2 and 3 have such a width that an extension region extending laterally from the left and right side edges of the coating sheet 1B is formed. Thereby, in the sealing part 50 mentioned below, sealing of the coating sheet 1B by both the covering sheets 2 and 3 can be performed successfully.

  Examples of the first and second cover sheets 2 and 3 include paper, non-woven fabric, film, and laminates thereof. For example, a resin film having air permeability or not having air permeability can be used. However, the present invention is not limited thereto, and an appropriate material is used depending on the specific use of the object of the present invention. It is preferable that at least one of them has air permeability.

  The stacked body 4 is introduced into the sealing portion 50. In the sealing part 50, the extension area | region from the coating sheet 1B in the 1st coating sheet 2 and the 2nd coating sheet 3 is joined by a predetermined joining means. Joining is performed outside the left and right side edges and outside the front and rear edges of the coating sheet 1B. Examples of the bonding means include heat fusion, ultrasonic bonding, and adhesion using an adhesive. Since the gap is provided between the coating sheets 1B adjacent in the front and rear in the re-pitch portion 40 described above, the region where the two covering sheets 2 and 3 are joined outside the front and rear edges of the coating sheet 1B is Sufficiently secured.

  The joining in the sealing part 50 is preferably performed so that a closed joining region surrounding the coating sheet 1B is formed. This joining region may be formed continuously, and may be performed so that the coating sheet 1B is in an airtight state by both the covering sheets 2 and 3, or may be formed intermittently.

  The laminated body 4 joined in this way is then introduced into the second cutting part 60 and cut across the width direction between the adjacent coating sheets 1B before and after in the running direction. Thereby, the target object 100 is obtained.

  According to the above method, unlike the technique described in Patent Document 1 described above, since the base material sheet 1 is cut before the coating liquid made of a viscous material is applied, the blade used for the cutting is used. It is effectively prevented that the coating liquid adheres. As a result, rust is effectively prevented from being generated on the blade, and the cutting performance of the blade is maintained for a long period of time, so that the production can be stably performed for a long period of time.

  FIG. 3 shows a modification of the apparatus shown in FIG. In the apparatus 10 shown in the figure, a nozzle 34 is disposed on the downstream side of the die coater 31 in the coating unit 30. This device isolates components that cause such chemical reactions when the coating solution made of viscous material is unstable, for example, when components contained in the coating solution cause chemical reactions. It is effective when you do not want to wake up. For example, when the component A and the component B contained in the coating liquid cause a chemical reaction, the coating liquid precursor made of a viscous material that contains the component A but does not contain the component B is isolated from the component A. In addition to this, a liquid containing component B is prepared separately, and the coating liquid precursor is applied to the individual base material sheet 1A by the die coater 31 to form the coating sheet precursor 1B ′. After that, the liquid containing the component B can be dropped by the nozzle 34 onto the individual base material sheet 1A. Further, Component B may be dropped intermittently on the base sheet 1B after the re-pitch. As an alternative to this method, in the apparatus shown in FIG. 3, the position of the arrangement of the die coater 31 and the nozzle 34 is reversed, and the liquid containing the component B is first applied to the individual base material sheet 1A by the nozzle 34. Then, the coating liquid precursor can be applied to the individual base material sheet 1A by the die coater 31. In addition, in the apparatus 10 shown in FIG. 3, the structure downstream from the coating part 30 is the same as that of the apparatus shown in FIG.

  FIG. 4 shows another apparatus 10 used in the manufacturing method of the present invention. This apparatus is different from the apparatus shown in FIG. 1 in the structure of the rotary die cutter 21 in the cutting section 20. Details are as described below.

  The base sheet 1 is fed out from a raw roll (not shown) and travels in the form of a continuous long object. Then, the base sheet 1 is introduced into the first cutting unit 20. In the 1st cutting part 20, the base material which consists of a continuous long thing so that several individual base sheet 1A may be formed along the running direction of the base material sheet 1 which consists of a continuous long thing. Cuts 5 having a closed shape are sequentially formed in the sheet 1. The cut 5 is a continuous line. In FIG. 4, a state is shown in which an elliptical cut 5 whose major axis faces the traveling direction of the base sheet 1 is formed. The blade provided in the rotary die cutter 21 has a shape corresponding to the shape of the notch 5. When the cut 5 is formed in the continuous long base material sheet 1, a suction source (not shown) connected to the anvil roller 22 in the first cutting part 20 is operated, and suction by the anvil roller 22 is performed. To do. By performing this suction, the notch 5 is formed, and even if the individual base material sheet 1A is generated, the base material sheet 1A is maintained in the state of being sucked to the peripheral surface of the anvil roller 22. The base sheet 1A travels without being separated from the continuous long base sheet 1. Further, in the manufacturing method of the present invention, instead of forming the closed-shaped cuts 5 described above, for example, cuts shown in FIG.

  The continuous long base material sheet 1 is introduced from the first cutting unit 20 to the coating unit 30 without being separated from the individual base material sheet 1A from the sheet 1, and is provided in the coating unit 30. Transfer to the endless belt 32. By the operation of the suction box 33 installed in the coating unit 30, the transfer of the continuous long base material sheet 1 and the individual base material sheet 1A to the endless belt 32 is performed smoothly. Therefore, even after the transfer to the endless belt 32, the individual base material sheet 1 </ b> A travels without being separated from the continuous long base material sheet 1.

  In the coating part 30, coating is performed so that the coating liquid which consists of a viscous body is applied to the whole region of the individualized base material sheet 1A. Preferably, coating is performed with a width exceeding the maximum width of the individual base material sheet 1A. By performing such coating, even if meandering occurs in the running of the continuous long base material sheet 1 in the coating part 30, the coating liquid is applied to the entire area of the individual base material sheet 1A. There is an advantage that it will be crafted.

  When the coating liquid is applied in the coating unit 30, the individual base material sheet 1A is not separated from the continuous base material sheet 1, and a gap is provided between them. Therefore, even if the coating liquid is continuously applied, the apparatus 10 including the endless belt 32 is not soiled by the coating liquid.

  When the apparatus shown in FIG. 4 is used, the pattern shown in FIG. 5A can also be adopted as the pattern of cuts formed in the continuous long base material sheet 1. In this case, a plurality of individual base sheet 1A and a plurality of individual base sheets 1D are formed. However, in this case, the individualized base sheet 1A is not an object. The individualized base material sheet 1A is to be separated and discarded, and the object is a base material having a notch C derived from each individual base material sheet 1A as shown in FIG. 5 (b). Sheet 1D.

  The individualized base material sheet 1A (hereinafter referred to as “individualized coating sheet 1B”) provided with the coating layer in this manner and the continuous length provided with the coating layer. The base material sheet 1 (hereinafter, referred to as “continuous coating sheet 1 </ b> C”) is separated from each other before being introduced into the re-pitch portion 40. More specifically, the individual coating sheet 1B is cut out from the continuous coating sheet 1C by the transfer pad 35 installed at the most downstream position of the coating part 30, and only the coating sheet 1B is repitched part 40. To be introduced. The continuous coating sheet 1C generated by separating the individualized coating sheet 1B is discharged out of the travel line. The subsequent steps are the same as the steps using the apparatus shown in FIG. 1, and the structure on the downstream side of the coating unit 30 in the apparatus 10 shown in FIG. 4 is the same as the apparatus shown in FIG.

  When the cutting pattern shown in FIG. 5 (a) is formed, the plurality of individualized coating sheets 1A are separated and discarded, and the remaining plurality of individualized coating sheets 1D (FIG. 5 ( b)) is the object. In this coating sheet 1D, a notch C derived from the individualized coating sheet 1D is formed. For example, a suction device (not shown) can be used for separating and discarding the coating sheet 1A. Moreover, the individualized coating sheets 1D may be re-pitched as necessary.

  FIG. 6 shows a modification of the apparatus shown in FIG. In the apparatus 10 shown in the figure, a nozzle 34 is disposed on the downstream side of the die coater 31 in the coating unit 30. This apparatus corresponds to the apparatus shown in FIG. 3 described above. In this apparatus, first, the coating liquid precursor is applied to the continuous long base material sheet 1 and the individual base material sheet 1 </ b> A by the die coater 31, and then another liquid is dropped by the nozzle 34. In FIG. 6, the liquid is dropped before the individualized coating sheet 1 </ b> B is separated, but instead, the liquid may be dropped intermittently after the coating sheet 1 </ b> B is separated.

  As an alternative to the method shown in FIG. 6, the positions of the die coater 31 and the nozzle 34 in FIG. 6 are reversed, the liquid is first dropped by the nozzle 34, and then the coating liquid precursor is applied by the die coater 31. You can also In addition, in the apparatus 10 shown in FIG. 6, the structure downstream from the coating part 30 is the same as that of the apparatus shown in FIG.

  In carrying out the production method of the present invention using each of the above devices, as the base material sheet, a material according to the intended use can be used without particular limitation. For example, fiber sheets such as paper, woven fabric, knitted fabric, and nonwoven fabric; resin films, metal foils; laminates thereof, and the like can be used. In particular, when a substrate sheet having liquid absorbency is used, the liquid component contained in the coating liquid is absorbed by the substrate sheet, so that the formed coating layer is fixed to the substrate sheet. There is an advantage that the performance is improved. In particular, it is ideal that the coating layer formed by the production method of the present invention has the coating film formed in a state of being uniformly dispersed with the powder component in a state where appropriate moisture is left in terms of product characteristics. Furthermore, it is desirable to form the coating layer in a state where the fibers and the powder component of the base sheet are entangled with each other, in order to prevent the powder component during use from being displaced. However, the composition of the coating layer in the final product is not fluid, and stable coating cannot be performed using a coating solution of the composition. It is necessary to do. However, since the coating layer formed from the diluted coating liquid contains a large amount of liquid, the product characteristics are deteriorated. In such a case, if a substrate sheet having liquid absorbency is used, such inconvenience is less likely to occur. From these viewpoints, it is preferable to use a fiber sheet which is a material having a high liquid absorbability and a good fixability of the coating layer as the base sheet. It is particularly preferable to use paper or non-woven fabric. Moreover, by using a fiber sheet, the water-soluble component is absorbed into the fiber sheet and the viscosity is lost, so that the separation property of the individualized coating sheet 1B is further improved.

  When a fiber sheet is used as the base sheet, both natural fibers and synthetic fibers can be used. By using hydrophilic fibers as the constituent fibers of the base sheet, there is an advantage that hydrogen bonds are easily formed with the oxidizable metal contained in the heat generating layer, and the shape retention of the heat generating layer is improved. . In addition, the use of hydrophilic fibers also has the advantage that the water absorption or water retention of the base sheet is improved and the water content of the heat generating layer can be easily controlled. From these viewpoints, cellulose fibers are preferably used as the hydrophilic fibers. Chemical fibers (synthetic fibers) and natural fibers can be used as the cellulose fibers.

  As chemical fibers of cellulose, for example, rayon and acetate can be used. As the natural cellulose fiber, various plant fibers such as wood pulp, non-wood pulp, cotton, hemp, wheat straw, and the like can be used. Of these natural cellulose fibers, it is preferable to use wood pulp from the viewpoint of easily obtaining thick fibers. The use of thick fibers as the natural cellulose fibers is advantageous from the viewpoint of water absorption or water retention of the base sheet.

  In particular, it is preferable to use bulky cellulose fibers as the natural cellulose fibers. By using the bulky cellulose fiber, it becomes easy to make the inter-fiber distance of the constituent fibers in the base sheet suitable. As specific examples of the bulky cellulose fiber, (a) the fiber shape has a three-dimensional structure of a twisted structure, a crimped structure, a bent and / or branched structure, or (b) the fiber roughness is 0.2 mg / m or more. Or (c) those in which the intramolecular and intermolecular molecules of the cellulose fiber are crosslinked.

Specific examples of the fiber having a three-dimensional structure such as a twisted structure, a crimped structure, a bent structure and / or a branched structure of (a) above include chemical pulp obtained by decomposing wood pulp by a chemical reaction, and mechanical treatment ( Pulp decomposed by beating) or pulp obtained by combining chemical reaction and mechanical treatment can be used.
Etc.

  Since the fibers of the above (b) accumulate cellulose fibers in a bulky state, when such fibers are used, the movement resistance of the liquid in the base sheet is small and the liquid passing speed is large. Control of liquid withdrawal from the layer is facilitated. From this viewpoint, the fiber roughness of the fiber (b) is preferably 0.2 to 3 mg / m, particularly preferably 0.2 to 1 mg / m.

  The fiber roughness is used as a scale representing the fiber thickness in fibers having non-uniform fiber thickness, such as wood pulp. For example, a fiber roughness meter (FS-200, KAJANNIELECTRONICSLTD. ). Examples of cellulose fibers with a fiber roughness of 0.2 mg / m or more include softwood kraft pulp (“ALBACEL” (trade name) from Federal Paper Board Co. and “INDORAYON” (trade name) from PT Inti Indorayon Utama. )] And the like.

The fiber (b) preferably has a roundness of the fiber cross section of 0.5 to 1, particularly 0.55 to 1. By using the cellulose fiber having such roundness, the movement resistance of the liquid in the base sheet is further reduced, and the passing speed of the liquid is further increased. The method of measuring roundness is as follows. The fiber is sliced perpendicular to the cross-sectional direction so that the area does not change, and a cross-sectional photograph is taken with an electron microscope. The cross-sectional photograph is analyzed by an image diffractometer [“Avio EXCEL” (trade name) manufactured by Nippon Avionics Co., Ltd.], and the cross-sectional area and circumference of the measurement fiber are measured. Using these values, the roundness is calculated using the following formula. The roundness is an average value obtained by measuring 100 arbitrary fiber cross sections.
Roundness = 4π (cross-sectional area of measurement fiber) / (peripheral length of cross-section of measurement fiber) ²

  When wood pulp is used as the bulky cellulose fiber, the cross section of the wood pulp is generally flattened by delignification treatment, and most of the roundness is less than 0.5. In order to make it 0.5 or more, for example, the wood pulp may be mercerized to swell the cross section of the wood pulp. Examples of commercially available mercerized pulp include “FILTRANIER” (trade name) manufactured by ITT Rayonier Inc. and “POROSANIER” (trade name) manufactured by the same company.

  The crosslinked cellulose fiber as the fiber (c) is preferable because it can maintain a bulky structure even in a wet state. Examples of the method for crosslinking the cellulose fiber include a crosslinking method using a crosslinking agent. Examples of such crosslinking agents include N-methylol compounds such as dimethylolethyleneurea and dimethyloldihydroxyethyleneurea; polycarboxylic acids such as citric acid, tricarballylic acid and butanetetracarboxylic acid; polyols such as dimethylhydroxyethyleneurea A cross-linking agent for polyglycidyl ether compounds. The amount of the crosslinking agent used is preferably 0.2 to 20 parts by weight with respect to 100 parts by weight of the cellulose fiber. The cross-linked cellulose fiber preferably has a fiber roughness of 0.3-2 mg / m, particularly 0.32-1 mg / m. The cross-linked cellulose fiber preferably has a roundness of the fiber cross section of 0.5 to 1, particularly 0.55 to 1. Examples of commercially available crosslinked cellulose fibers include “High Bulk Additive” manufactured by Weyerhaeuser Paper Co.

  Among the fibers (a) to (c) described above, particularly when the fiber (c) is used, the integrity of the base sheet and the heat generating layer is enhanced, and the advantageous effect that the heat generating layer is less likely to fall off. Is played. Further, the heating element becomes flexible, and there is an advantageous effect that the fitting property is improved when the heating tool of the present invention is attached to an object to be attached, for example, the skin or clothing of a human body. Surprisingly, it is worth noting that the flexibility of the heating element is maintained even after the end of heat generation. The base sheet is preferable because it further enhances the property of absorbing and holding the liquid. Since the base material sheet using this fiber becomes flexible, there is also an advantageous effect that the fitting property is improved when the object of the production method of the present invention is attached to, for example, human skin or clothing. .

  The above-mentioned various hydrophilic fibers preferably have a fiber length of 0.5 to 6 mm, particularly 0.8 to 4 mm, from the viewpoint of easy production of a substrate sheet by a wet method or a dry method.

  In addition to the above-described hydrophilic fibers, heat-fusible fibers may be blended in the base sheet as necessary. By blending this fiber, the strength of the substrate sheet in a wet state can be increased. The compounding amount of the heat-fusible fiber is preferably 0.1 to 10% by mass, particularly 0.5 to 5% by mass, based on the total amount of fibers in the base sheet.

  In order to further enhance the property of the base sheet to absorb liquid, it is advantageous not only to select fibers but also to contain a material that absorbs liquid in the base sheet. For example, it is advantageous to include particles of superabsorbent polymer. As the superabsorbent polymer, it is preferable to use a hydrogel material that can absorb and hold a liquid having a weight 20 times or more of its own weight and can be gelled. The shape of the particles can be spherical, massive, grape bunches and the like. The particle size of the particles is preferably 1 to 1000 μm, particularly preferably 10 to 500 μm. Specific examples of superabsorbent polymers include starch, crosslinked carboxylmethylated cellulose, polymers or copolymers of acrylic acid or alkali metal acrylates, polyacrylic acid and salts thereof, and polyacrylate graft polymers. Is mentioned.

  When the base sheet contains superabsorbent polymer particles, the base sheet can be a one-ply sheet in which (a) the superabsorbent polymer particles and fibers are uniformly mixed. In the base sheet, (b) the superabsorbent polymer particles are mainly present in a substantially central region in the thickness direction of the base sheet, and the particles are substantially present on the surface of the base sheet. It can also be one-ply with a structure that is not. Further, the base sheet may be (2) a two-ply type in which particles of a superabsorbent polymer are arranged between the same or different fiber sheets containing fibers.

  The substrate sheet can be produced by, for example, the airlaid method when it is in the form of (a). In the case of (b), it can be produced, for example, by the wet papermaking method described in JP-A-8-246395 related to the previous application of the present applicant. In the case of (c), it can be produced by the airlaid method or the wet papermaking method. Of these base sheets that can take various forms, it is preferable to use those in the form (b) from the viewpoint of improving the liquid absorption retention.

  The ratio of the superabsorbent polymer in the base sheet is 10 to 70% by weight, particularly 20 to 55% by weight, and the viewpoint of making the water absorption or water retention of the base sheet suitable and the heat generating layer This is preferable from the viewpoint of controlling the water content. In addition, this ratio is the value measured about this base material sheet in the dry state before a coating layer is formed on a base material sheet.

The base sheet preferably has a basis weight of 10 to 200 g / m ² , particularly 35 to 150 g / m ² . By setting the basis weight of the base sheet within this range, sufficient strength of the base sheet in a wet state can be secured, and water absorption or water retention of the base sheet should be suitable. Can do. On the other hand, the basis weight of the superabsorbent polymer contained in the base sheet is preferably 5 to 150 g / m ² , particularly 10 to 100 g / m ² . By setting the basis weight of the superabsorbent polymer within this range, the water absorption or water retention of the base sheet can be further improved. These basis weights are values measured for the base sheet in a dry state before the coating layer is formed on the base sheet.

  Next, the viscous body used in the production method of the present invention will be described. As the viscous body, a material according to the intended use can be used without particular limitation. For example, emulsions, viscous oils, water-containing gels, dye inks, resin paints, waxes, hot melts, viscous substances that do not contain solids such as liquid detergents, pigment inks, magnetic paints, conductive paints, insulating paints, viscous paints It is possible to use a powdered detergent, a viscous material containing a solid content such as a liquid obtained by thickening an oxidizable metal with water or gel. Considering that the method of the present invention is particularly effective in preventing the cutting performance of the cutting blade from being deteriorated, the advantage of the present invention is particularly remarkable when a viscous material containing a solid content is used. It becomes.

  As an example of a viscous material containing a solid content, an exothermic composition containing particles of an oxidizable metal, an electrolyte, and water can be given. This exothermic composition may further contain a reaction accelerator. Moreover, the thickener and surfactant may be included from a viewpoint of improving the dispersibility of solid content in a viscous body. A sheet-like heating element can be obtained by directly applying a viscous material containing these components onto the surface of the base sheet to form a coating layer. When the base sheet has liquid absorbability, simultaneously with the application of the viscous body, the liquid component contained in the viscous body is absorbed by the base sheet, and the viscosity of the viscous body decreases. As a result, the coating layer loses its viscosity, and the coating layer adheres to the first coating sheet 2 when the first coating sheet 2 is disposed on the coating layer in the re-pitch portion 40 described above. Is effectively prevented. As a result, when the first cover sheet 2 is, for example, a sheet having air permeability (for example, a porous sheet having moisture permeability made of a synthetic resin), the sheet is difficult to be clogged with solid content, and the air permeability is reduced. Is effectively prevented. In addition to using a sheet having liquid absorbency as the base sheet, if suction is performed by the suction box 33 during the application of the viscous material, the drawing of the liquid from the viscous material is further promoted, and the coating layer The viscosity can be reduced more rapidly.

  In the viscous body composed of the exothermic composition described above, if the particles of the oxidizable metal, the electrolyte, and water coexist, the oxidation of the particles of the oxidizable metal is promoted. It is advantageous to keep the particles and electrolyte separate. From this point of view, when using a viscous body made of the above-described exothermic composition, the apparatus shown in FIG. 3 is used, and a composition containing oxidizable metal particles and water as the viscous body and not containing an electrolyte is used. The base material sheet 1A is coated with the viscous material and before the distance between the individual base material sheets 1A having the coating layer is increased. It is preferable to add an aqueous solution of the electrolyte. Conversely, the aqueous electrolyte solution is added to the individualized base material sheet 1A after cutting the base material sheet 1 made of a continuous long material and before the application of the viscous material. It is also preferable to do.

  When the oxidizable metal particles and the electrolyte are separated, the apparatus shown in FIG. 6 can be used instead of the apparatus shown in FIG. When the apparatus shown in FIG. 6 is used, a composition containing oxidizable metal particles and water as a viscous material and not containing an electrolyte is used, and the viscous material is applied to the base sheet 1 made of a continuous long material. After coating, before separating the individual base material sheet 1A from the base material sheet 1 made of a continuous long material having a coating layer, the base material sheet 1 made of the continuous long material It is preferable to add an aqueous solution of the electrolyte to the above. On the contrary, the aqueous electrolyte solution is formed after the slit 5 is formed in the base material sheet 1 made of a continuous long material, and before the application of the viscous material, from the continuous long material. It is also preferable to add to the base sheet 1 to be formed.

  As mentioned above, although this invention was demonstrated based on the preferable embodiment, this invention is not restrict | limited to the said embodiment. For example, in the above-described embodiment, a die coater is used for coating a coating liquid made of a viscous material, but other coating means such as roll coating, screen printing, roll gravure, knife coating, and curtain coater are employed. May be.

  Moreover, also in the manufacturing apparatus shown in FIG. 3, in the position before performing the process of isolate | separating the individualized base material sheet 1A from the base material sheet 1 which consists of a continuous long thing, the coating layer division | segmentation shown in FIG. A means similar to the means 36 may be provided. Moreover, also in the manufacturing apparatus shown in FIG.4 and FIG.6, before separating the individualized base material sheet 1A from the base material sheet 1 made of a continuous long object, and at a position before the delivery pad 35, A means similar to the coating layer dividing means 36 shown in FIG. 1 may be provided.

DESCRIPTION OF SYMBOLS 1 Base material sheet 1A Individualized base material sheet 1B The individualized base material sheet in which the coating layer was formed 10 Manufacturing apparatus 20 1st cutting part 30 Coating part 40 Re-pitch part 50 Sealing part 60 2nd cutting Part

Claims (11)

A method for producing a sheet having a coating layer by applying a viscous material to a base sheet,
While running the base sheet composed of continuous long objects, sequentially cutting the base sheet over the direction intersecting the running direction, to obtain a plurality of individual base sheets,
Applying a viscous material to one surface of each individualized base sheet while running the individual base sheets in a state where they are arranged without a gap before and after their running direction. To form a coating layer,
The manufacturing method of the sheet | seat which has a coating layer which makes each individual base-material sheet | seat which has a coating layer extend the distance between this sheet | seat so that a clearance gap may arise before and behind those running directions. A method for producing a sheet having a coating layer by applying a viscous material to a base sheet,
While running a base sheet made of a continuous long object, the base sheet is cut in a closed shape so that a plurality of individual base sheets are formed along the running direction of the base sheet. Forming sequentially,
A base sheet made of a continuous long material with cuts formed is made of the continuous long material while running without separating the individual base material sheet from the base material sheet made of the continuous long material. Apply a viscous material on one side of the base sheet to form a coating layer,
Separating each individual base material sheet from a base material sheet composed of a continuous long material having a coating layer to obtain a plurality of individual base material sheets having a coating layer, The manufacturing method of the sheet | seat which has. A method for producing a sheet having a coating layer by applying a viscous material to a base sheet,
While running a base material sheet made of a continuous long material, in order to form a plurality of individual base material sheets along the running direction of the base material sheet, in order to form a cut in the base material sheet,
A base sheet made of a continuous long material with cuts formed is made of the continuous long material while running without separating the individual base material sheet from the base material sheet made of the continuous long material. Apply a viscous material on one side of the base sheet to form a coating layer,
A part of each individual base material sheet is separated and discarded from a base material sheet made of a continuous long material having a coating layer, and it is derived from a base material sheet having a coating layer and separated and discarded. The manufacturing method of the sheet | seat which has a coating layer which obtains the several individual base material sheet which has a notch part to do.   The manufacturing method according to any one of claims 1 to 3, wherein the base sheet has a liquid absorptivity.   The manufacturing method according to any one of claims 1 to 4, wherein the viscous material is a heat generating composition containing particles of an oxidizable metal, an electrolyte, and water.   The production method according to any one of claims 1 to 4, wherein the viscous material is a composition containing particles of oxidizable metal and water and no electrolyte.   The manufacturing method of Claim 6 which adds the aqueous solution of electrolyte with respect to the base material sheet in which the individualized base material sheet or the notch | incision was formed before application of a viscous body.   The manufacturing method of Claim 6 which adds the aqueous solution of electrolyte with respect to the base material sheet | seat in which this viscous body was coated after application of a viscous body.   The manufacturing method according to claim 8, wherein an aqueous solution of the electrolyte is added before increasing the distance between the individualized base sheets or before separating the individual base sheets.   The manufacturing method of Claim 8 which adds the aqueous solution of an electrolyte after extending the distance between the individualized base material sheets or isolate | separating the individualized base material sheet.   The manufacturing method as described in any one of Claims 1 thru | or 10 which performs a coating layer division | segmentation process before extending the distance between the individualized base material sheets or isolate | separating the individualized base material sheet.

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