JP2012135353A - Method for manufacturing brush, and brush - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a brush that can enhance the fiber density of brush bristles, and improve the manufacturing efficiency in manufacturing the brush, and to provide a brush manufactured by the method.SOLUTION: The method for manufacturing the brush includes the steps of: extending a brush base material made of a stretchable and elastic elastomer resin at an elongation rate of 50-400%; applying an adhesive to the brush base material at a predetermined interval; warping brush bristle filaments; continuously pressing an implant member in the perpendicular direction of the warped brush bristle filaments to implant the brush bristle filaments in the brush base material; and shrinking the brush base material.

Description

The present invention relates to a brush manufacturing method capable of significantly increasing the fiber density of the brush fibers and improving the production efficiency in manufacturing the brush, and a brush obtained by using the brush manufacturing method.

Brushes composed of brush bases and brush fibers are used in various fields, and in particular, are suitably used as brushes for performing various processes such as cleaning, cleaning, charging, coating, grinding, and polishing. For example, in a manufacturing process, a cleaning brush used for cleaning or removing foreign matter has a problem that the quality of a product obtained is deteriorated due to the presence of foreign matter if the cleaning is insufficient.

On the other hand, as an example using a commonly used charging brush, as shown in Patent Document 1 and Patent Document 2, a conductive fiber composed of a conductive fiber excellent in charging performance and static elimination performance and a brush base is used. An articulated brush is disclosed that is formed by spirally winding and joining a support shaft made of a metal round bar.

However, with the recent technological innovation, the conventional conductive brush has insufficient removal capability. In addition, conventional conductive brushes have a problem in that the conductive fibers (brush fibers) sag as they are used, and it is difficult to maintain charging performance and cleaning performance over a long period of time.
Further, in the conventional conductive brush, the brush base is easily peeled off from the support shaft, and not only can the role of the conductive brush not be fulfilled sufficiently, but also the device itself may be destroyed.

Also, conventional conductive brushes are manufactured by applying an adhesive to one end of the brush fiber and fixing it to the brush base, or by brushing the brush fiber by pile weaving and weaving it into the brush base. ing.
However, the method of fixing with an adhesive has a problem that the fiber density of the brush fibers cannot be increased and a problem that the brush fibers are easily pulled out.
Further, the method of raising by pile weaving has a problem that not only the fiber density of the brush fibers is lowered, but also the weaving process becomes complicated and the working efficiency is lowered.

JP 2000-56538 A JP 2004-93948 A

An object of the present invention is to provide a method for manufacturing a brush capable of significantly increasing the fiber density of brush fibers and improving the production efficiency when manufacturing the brush. To do.

The present invention relates to a step of extending a base material for a brush substrate made of a stretchable elastic elastomer resin at an elongation rate of 50 to 400%, a step of applying an adhesive to the base material for a brush substrate at predetermined intervals, a yarn for a brush fiber The step of warping, the step of continuously implanting the yarn for the brush fiber on the substrate for the brush substrate by pressing the implantation member from the vertical direction of the warped brush fiber yarn, and for the brush substrate It is a manufacturing method of the brush which has the process of shrinking a base material.
The present invention is described in detail below.

Conventionally, as a method for manufacturing a brush, a method in which an adhesive is applied to one end of a brush fiber and the brush fiber is fixed to the brush base, or a method in which the brush fiber is raised by a pile weave and woven into the brush base is used. However, there has been a problem that the fiber density of the brush fibers cannot be increased and a problem that work efficiency is lowered.
In the method for manufacturing a brush of the present invention, by using the above-described method, the fiber density of the brush fiber can be significantly increased, and the production efficiency when manufacturing the brush can be improved. Moreover, the brush obtained is one in which the brush fibers are not easily detached.

An example of the manufacturing method of the brush of this invention is demonstrated using FIGS.
1 to 7 are cross-sectional views from the lateral direction. Moreover, although the flat plate base material for brush bases is used in the figure, it is not limited to a flat plate shape.

In the present invention, first, a sheet-like base material 12 for a brush base made of an elastic elastic elastomer resin is stretched at an elongation rate of 50 to 400% and fixed in that state (FIG. 1).
Next, the adhesive 13 is applied to the extended brush base material 12 at a predetermined interval.
Thereafter, the yarn 11 for brush fibers is warped at an appropriate interval and fixed in an extended state. Next, after the warped yarn 11 for brush fibers is gripped by the fiber gripping portions 15a and 15b (FIG. 2), the implant member 14 is pressed from the vertical direction of the yarn 11 for brush fibers to press the yarn 11 for brush fibers. Is implanted in the brush substrate 12 (FIG. 3). And this process is performed continuously (FIGS. 4 and 5). The crease part of the yarn 11 for brush fibers is cut as needed.
The brush base material 12 in which the brush fiber yarns 11 thus obtained are planted is released from the stretched state (FIG. 6), whereby a brush having the brush base 2 and the brush fiber 1 is obtained. It is produced (FIG. 7).

In the manufacturing method of the brush of this invention, the process of extending | stretching the base material for brush base | substrates which consists of an elastic elastic elastomer resin by 50 to 400% of elongation rate first is performed. Specifically, a method of fixing and pulling a plurality of parts of a base material for a brush base, a method of fixing a plurality of parts of a base material for a brush base and expanding or pressing a non-fixed part from one side of the base material, A method of extending a base material for a brush substrate along a cylindrical body, a cone, a roll having a tapered shape, etc., or a method of extending by stretching a plurality of rolls and / or moving a fixed part , Etc.

The elongation percentage of the brush base material is 50 to 400%. When the elongation percentage is less than 50%, the fiber density of the brush fibers is lowered, and when it exceeds 400%, the base material for the brush base is deteriorated. Preferably it is 100 to 300%.
The elongation rate is expressed as a percentage (%) obtained by dividing the difference between the length after elongation and the length before elongation by the length before elongation. Further, when the brush base material is in the form of a sheet, the length after extension and the length before extension refer to the length in the extension direction, and when the brush base material is in a tube shape, the length is extended. The rear length and the length before extension refer to the length of the outer circumference, respectively.

As the base material for the brush base, one made of a stretchable elastic elastomer resin is used.
Further, the shape of the brush base material may be a flat plate shape (sheet shape) or a cylindrical shape (tube shape). In addition, when the said base material for brush base | substrates is flat form, thickness of about 200-3000 micrometers is preferable.

8 and 9 show a part of the manufacturing method in the case where a tube-shaped substrate is used as the brush base material. 8 corresponds to FIG. 6, and FIG. 9 corresponds to FIG.
Even when such a tube-shaped base material for a brush substrate is used, as in the case of a sheet (FIGS. 1 to 5), the brush base material 22 is stretched at an elongation rate of 50 to 400%, and then bonded. By applying the agent 23 and continuously planting the brush fiber yarns 21, the brush base material 22 having the brush fiber yarns 21 implanted therein is obtained (FIG. 8).
Next, a tube-like brush having the brush base 2 and the brush fiber 1 is produced by releasing the extended state of the brush base material 22 on which the brush fiber yarns 21 are planted (FIG. 9). .

The stretch elastic elastomer resin (hereinafter also simply referred to as an elastomer resin) returns to its original length even when stretched (has no yield point within the stretchable range), that is, rubber elasticity (10% in the hysteresis curve). There is no particular limitation as long as it is a thermoplastic elastomer. Examples of the elastomer resin include polyurethane and polystyrene butadiene block copolymers, and polyurethane elastomer is particularly preferable.

The elastomer resin preferably has a tensile elongation of 100 to 900%. By setting the tensile elongation within the above range, the tensile elongation can be reliably fixed to the support shaft. The tensile elongation is more preferably 100 to 600%.
The tensile elongation can be measured by a method based on JIS K7311.

The tensile strength (JIS K7311) of the elastomer resin is preferably about 30 to 60 MPa, more preferably about 45 to 60 MPa. The surface hardness A (JIS K 6253) is preferably about A70 to 98, and more preferably A80 to 90. When the surface hardness A is less than A70, it is difficult to ensure the strength, and when it exceeds A98, the elongation and stretchability tend to be extremely deteriorated.

Specific examples of the elastomer resin include, for example, Kuramilon U (manufactured by Kuraray Co., Ltd.) 3195, 8175, which is a thermoplastic polyurethane elastomer, Pandex (manufactured by DIC Bayer Polymer Co., Ltd.) T-1185N, 1190N, 1195N and the like. .

As an example of the method for producing the elastomer resin, a method for producing a polyurethane elastomer resin is shown below. The polyurethane elastomer resin can be produced, for example, from an aromatic polyisocyanate and a polyol using a known method such as a one-shot method or a prepolymer method.

Examples of the aromatic polyisocyanate include aromatic diisocyanates having 6 to 20 carbon atoms (excluding carbon in the NCO group, the same shall apply hereinafter), modified products of these aromatic diisocyanates (carbodiimide groups, uretdione groups, uretoimine groups, urea groups). And the like, and mixtures of two or more thereof.

Examples of the aromatic polyisocyanate include 1,3- and / or 1,4-phenylene diisocyanate, 2,4- and / or 2,6-tolylene diisocyanate, 2,4′- and / or 4,4′-. Examples include diphenylmethane diisocyanate (hereinafter abbreviated as MDI), 4,4′-diisocyanatobiphenyl, 3,3′-dimethyl-4,4′-diisocyanatodiphenylmethane, 1,5-naphthylene diisocyanate, and the like. Of these, MDI is particularly preferable.

Examples of the polyol include polyether-based, polyester-based, polycarbonate-based, and aliphatic-based polyols, and polyether-based or polyester-based polyols are particularly preferable.
The number average molecular weight of the polyol is preferably 300 or more, more preferably 1000 or more, still more preferably 2000 or more, preferably 4000 or less, more preferably 3500 or less, and still more preferably 3000 or less, from the viewpoint of elasticity.

In the method for manufacturing a brush of the present invention, a step of applying an adhesive at a predetermined interval to the brush base material is then performed.
Since the space | interval at the time of applying the said adhesive agent is determined according to the fiber density of the brush obtained, it is although it does not specifically limit, It is preferable to set it as every 0.5-2 mm. By setting the interval at the time of applying the adhesive within the above range, a brush having a high fiber density is obtained.
The adhesive is not particularly limited as long as it can fix the brush fibers, and for example, a thermoplastic elastomer such as EVOH, a polyurethane-based, epoxy-based, or silicone-based adhesive can be used.

In the method for producing a brush of the present invention, a step of warping the yarn for brush fibers is then performed.
Since the warp density of the yarn for brush fibers is determined according to the fiber density of the obtained brush, it is not particularly limited, but 15 to 200 yarns / cm can be exemplified.

Cotton yarn, polyester fiber, polyamide fiber, conductive fiber, etc. can be used as the yarn for the brush fiber.
The yarn for brush fibers may be a filament. Monofilament or multifilament can be used as the filament, but it is preferable to use multifilament.

Examples of the polyester fiber include polyethylene terephthalate, polybutylene terephthalate, polypropylene terephthalate, a copolymer obtained by copolymerizing a dicarboxylic acid component, a diol component or an oxycarboxylic acid component, or a polyester blended with these polyesters. Is mentioned. Furthermore, aliphatic polyesters such as polylactic acid, polybutylene succinate and polyε-caprolactam known as biodegradable polyesters may be used.

Examples of the polyamide fiber include nylon 6, nylon 66, nylon 69, nylon 46, nylon 610, nylon 12, polymetaxylene adipamide, and fibers made by copolymerizing or blending these components. Can be mentioned.

Examples of the conductive fibers include carbon fibers, composite fibers obtained by kneading carbon black into synthetic fibers such as nylon, acrylic and polyester, and synthetic fibers whose surface is coated with carbon black.
Specific examples of the conductive fibers include conductive rayon fibers REC-B, REC-C, REC-M1, REC-M10 (manufactured by Unitika Ltd.), SA-7 (manufactured by Toray Industries, Inc.), Thunderon (Nippon Eyelashes) There are commercially available products such as Berton (manufactured by KB Seiren), Kurabobo (manufactured by Kuraray), and Roval (manufactured by Mitsubishi Rayon).

Although the thickness of the said yarn for brush fibers is not specifically limited, It is preferable that a fiber diameter is 5-300 micrometers. When the fiber diameter of the yarn for brush fibers is less than 5 μm, the fiber becomes weak, the brushing effect utilizing the rebound resilience of the fiber is difficult to obtain, and the fiber sag by continuous use tends to be fast. .
If the fiber diameter of the yarn for brush fibers exceeds 300 μm, uniform contact with the object to be brushed tends to be difficult to obtain, which is not preferable. By setting the thickness of the yarn for brush fibers within the above range, the brush has excellent uniform contact by brushing.

Next, in the present invention, a step of continuously planting the brush fiber yarn on the brush base material by pressing the implantation member from the vertical direction of the warped brush fiber yarn is performed.
By performing such a process, it is possible to greatly increase the production efficiency of the brush as compared with the method of sequentially planting the yarn for the brush fiber that has been cut into an appropriate length in advance.

The implanting member is not particularly limited as long as it has a shape that can operate in the vertical direction and can be implanted with yarns for brush fibers. For example, it can move up and down and has a width toward the tip. Examples of the member are narrow. Further, as the material, a material that is thin but does not deform is preferable, and specifically, a metal is preferable. Further, from the viewpoint of imparting peelability, it is preferable that the surface is subjected to fluorine processing or the like.

Specifically, as the planting step, as shown in FIGS. 3 to 5, after fixing the yarn for brush fibers sized with one set of two gripping bars, another set of gripping bars is The warped fiber is supported only by the gripping bar at the bottom of the released state. Next, press the yarn for the brush fiber from the upper part between the two sets of gripping rods, and after planting it on the base material for the brush substrate through the adhesive, fix the one set of gripping rods that were open In addition, a method of opening another set of gripping bars that have been fixed can be used.
Thereafter, by repeatedly performing the planting step, it becomes possible to plant the yarn for the brush fiber continuously.
Note that the method is not particularly limited as long as it is possible to continuously plant the yarn for the brush fiber by pressing the implantation member.

In this invention, the process of cutting the yarn for brush fibers after performing an planting process into an appropriate length is performed as needed.

In this invention, the brush which has a brush base | substrate and a brush fiber is then producible by performing the process which shrinks | contracts the said base material for brush base | substrates next. The method for shrinking the base material for the brush base is not particularly limited as long as it can relieve the stretching stress in the stretching step. For example, the method for releasing the fixing of the base material for the brush base performed in the stretching step. Alternatively, a method of applying pressure in the horizontal direction can be mentioned.
By performing such a process, the fiber density of the obtained brush can be increased.

In the above step, heating may be performed. Although the temperature at the time of heating is determined according to the kind of base material for brush bases to be used, it is not specifically limited, However, 120-200 degreeC is preferable. A more preferable range of the temperature is 120 to 190 ° C, more preferably 120 to 180 ° C. By setting the temperature at the time of heating within the above range, the brush fiber can be contracted without adversely affecting the physical properties and dimensions of the brush fiber.

In the case of pressurizing in the horizontal direction, the pressure at the time of pressurizing in the horizontal direction is not particularly limited because it is determined according to the type of the base material for the brush base to be used, but 100 to 10,000 Pa is preferable. By setting the pressure applied in the horizontal direction within the above range, the entire brush can be integrated without being deformed.

In the method for manufacturing a brush of the present invention, wefts 3 may be inserted between the brush fibers 1 as shown in FIG. By inserting such a weft, it becomes difficult for the brush fiber to come off, and it is possible to suppress a dimensional change in the weft direction.
As the weft, a highly rigid fiber such as polyester or a metal fiber can be used.

As a method of inserting the weft yarn between the brush fibers, for example, the implant member is pressed from the vertical direction of the warped brush fiber yarn so that the brush fiber yarn is continuously planted on the brush base material. In the step of setting (FIGS. 3 to 5), a method of inserting the wefts between the brush fibers by continuously planting in advance with the wefts set in the distal end portion of the implantation member can be mentioned.

By using the method for manufacturing a brush according to the present invention, compared to a conventional method for manufacturing a brush, the fiber density of brush fibers can be increased and a brush that can be reliably fixed to a support shaft is manufactured. be able to. Such a brush is also one aspect of the present invention.

The brush of the present invention has a brush base and brush fibers.

The length of the brush fibers is preferably 2 to 30 mm. If the length of the brush fiber is less than 2 mm, it is difficult to obtain uniform contact with the object to be brushed using the elasticity of the fiber. When the length of the brush fiber exceeds 30 mm, it is difficult to obtain a brushing effect utilizing the rebound resilience of the fiber, and there is a tendency that the settling of the fiber due to continuous use tends to be accelerated, which is not preferable. By setting the length of the brush fibers within the above range, the brush has excellent uniform contact by brushing.

Furthermore, the fiber density of the brush fiber is preferably 10,000 to 200,000 pieces / cm ² . By making the fiber density of the brush fiber within the above range, the uniform contact between the brush and the brushing object is less affected by the positional accuracy between the brush and the brushing object, and the uniform contact is possible regardless of the assembly accuracy. An excellent brush.

The shape of the brush of the present invention is not particularly limited, but it is preferable that the brush base has a cylindrical shape and has brush fibers on the cylindrical outer surface of the brush base. By having such a shape, it becomes easy to adapt to the main shafts of various diameters, and fixing to the main shaft by heat treatment becomes easy.

The brush of the present invention can be suitably used as a cleaning brush. It can also be used for applications that require brushing and polishing. Furthermore, it can be used suitably also for a charging brush and a static elimination brush.

By using the brush manufacturing method of the present invention, the fiber density of the brush fibers can be increased and the work efficiency of brush production can be greatly improved as compared with the conventional brush manufacturing method. For example, when the brush of the present invention is used for a cleaning brush, a charging brush, a static elimination brush, a transfer brush, etc., it has excellent performance such as cleaning property and charging property.

It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically another example of the manufacturing method of the brush of this invention. It is drawing which shows typically another example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the brush obtained with the manufacturing method of the brush of this invention.

Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

Example 1
As shown in FIG. 1, a polyurethane substrate (width 15 mm, length 150 mm, thickness 500 μm, tensile elongation 525%) is stretched in the fiber warping direction at an elongation rate of 100%, and then 1 mm long (1 mm interval) Then, an adhesive (PM165 manufactured by Cemedine Co., Ltd.) was applied.
Thereafter, the polyester yarn (Shappe span # 90) was warped at a warping density of 20 yarns / 12 mm and fixed in an extended state. Next, as shown in FIGS. 2 and 3, the warped polyester yarn was gripped by two sets of fiber gripping portions, and then the implantation member was pressed from the vertical direction of the polyester yarn to plant the polyester yarn on the polyurethane base material. . 200 polyester yarns were implanted in the polyurethane base material by cutting the crease part of the polyester yarn and continuously performing this process.
Next, as shown in FIG. 6, the polyurethane base material on which the polyester yarn was implanted was returned to an unstretched state, and heated at 50 ° C. for 5 minutes to produce a brush.
The obtained brush had a fiber density of 18,000 fibers / cm ² and a brush hair length of 2 mm. The brush base had a thickness of 0.6 mm, a width of 16 mm, and a length of 150 mm.

(Example 2)
Example 1 except that conductive nylon fibers (Bertlon, KB Selen, 88 dtex / 12f) were used instead of the polyester yarn (Shappe span # 90), and the sizing density was 200 pieces / 10 mm. Thus, a brush was produced.
The obtained brush had a fiber density of 24,000 fibers / cm ² and a brush hair length of 2 mm. The brush base had a thickness of 0.6 mm, a width of 16 mm, and a length of 150 mm.

(Comparative Example 1)
A brush was produced in the same manner as in Example 1 except that the polyurethane base material was not stretched.
The obtained brush had a fiber density of 9000 fibers / cm ² and a brush hair length of 2 mm. The thickness of the brush base was 0.5 mm, the width was 15 mm, and the length was 150 mm.

(Comparative Example 2)
A brush was produced in the same manner as in Example 1 except that the polyurethane substrate was changed to a polyethylene substrate (tensile elongation of 15%) and the polyurethane substrate was not stretched.
The obtained brush had a fiber density of 9000 fibers / cm ² and a brush hair length of 2 mm. The thickness of the brush base was 0.5 mm, the width was 15 mm, and the length was 150 mm.

(Evaluation)
(Mountability to the spindle)
The brushes obtained in Examples 1 and 2 were cut out to a width of 47.5 mm, and both ends thereof were preheated with a non-adhesive processing mold heated to 180 ° C., and then wound around a SUS304 shaft having an outer diameter of 15.5 mm. The both ends were fused together to obtain a brush-coated roll body.

As a result, the brush-coated roll body produced from the brushes obtained in Examples 1 and 2 could be easily coated. In addition, the brush and the SUS shaft were firmly fixed by performing a heat treatment at 120 ° C. for 5 minutes and cooling to room temperature.

On the other hand, the brush obtained in Comparative Example 2 was cut out to a width of 47.5 mm, and both ends thereof were preheated with a non-adhesive processing mold heated to 180 ° C., and then applied to a SUS304 shaft having an outer diameter of 15.5 mm. While winding, the both ends were fused to each other to try to obtain a brush-coated roll body, but the brush was difficult to stretch, it was difficult to butt both ends, and could not be attached to the SUS shaft. .

ADVANTAGE OF THE INVENTION According to this invention, the fiber density of a brush fiber can be raised significantly and the manufacturing method of the brush which can improve the production efficiency at the time of manufacturing a brush, and the manufacturing method of this brush are used. Can be provided.

Claims (4)

A step of stretching a base material for a brush base made of a stretchable elastic elastomer resin at an elongation rate of 50 to 400%;
A step of applying an adhesive at a predetermined interval to the base material for the brush substrate;
Warping the yarn for brush fibers,
A step of continuously planting the brush fiber yarn on the base material for the brush base by pressing the implantation member from the vertical direction of the warped yarn for the yarn, and
A method for producing a brush, comprising the step of shrinking the base material for a brush base. 2. The method for manufacturing a brush according to claim 1, wherein the brush base material is made of a stretchable elastic elastomer resin having a tensile elongation of 100 to 900%. The method for producing a brush according to claim 2, wherein the elastic elastic elastomer resin is a polyurethane elastomer. The brush manufactured using the manufacturing method of the brush of Claim 1, 2, or 3.

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