JP2023184522A - Method and apparatus for manufacturing air permeable product - Google Patents

Abstract

To provide a method and an apparatus for manufacturing an air permeable product which can provide an air permeable product having an adhesive layer having an appropriate layer thickness in a part exposed to a surface of an air permeable base material.SOLUTION: A method for manufacturing an air permeable product performs the steps of: preparing an air permeable base material (S1) having a gap on at least one surface side; and preparing an adhesive layer (N) for being formed in a part on the one surface side, and controlling hardness of the adhesive layer (N) so that only a part of the adhesive layer (N) enters into a gap of the air permeable base material (S1). A range of the adhesive layer (N) entering into the air permeable base material (S1) can be controlled by pressing the adhesive layer (N) whose hardness is controlled against the air permeable base material (S1). Thereby, an air permeable product (F) whose layer thickness is made appropriate in a part exposed to the surface of the adhesive layer (N) can be obtained. A part of the adhesive layer (N) enters into the gap of the air permeable base material (S1), thereby both of them are integrated to increase bonding strength after curing, which can suppress adhesive residues when being peeled from a mounting object.SELECTED DRAWING: Figure 1

Description

The present invention relates to a technology for manufacturing breathable products such as filters, and particularly relates to a manufacturing method and a manufacturing apparatus for manufacturing a breathable product having an adhesive layer on a part of one side of a breathable base material. It is something.

BACKGROUND ART Conventionally, breathable products such as filters have been manufactured using breathable materials such as woven fabrics to prevent dust and the like from entering a room through vents. Further, in order to facilitate attachment to a vent hole, such a filter may have an adhesive layer formed on one side of a breathable base material made of nonwoven fabric or the like.

Japanese Patent No. 6178291 describes a method for manufacturing a filter in which an adhesive layer made of a hot melt adhesive is provided on one side of a nonwoven fabric serving as a base material. In the manufacturing method disclosed in Japanese Patent No. 6178291, a letterpress roll that has a predetermined convex pattern and is driven to rotate, and a pressing roller that rotates in contact with the letterpress roll are prepared, and the convex pattern is After applying a hot melt adhesive on the top, the hot melt adhesive applied to the convex pattern of the letterpress roll is transferred onto the nonwoven fabric by passing the nonwoven fabric between a letterpress roll and a pressing roller, and then , describes a method of manufacturing a filter having a hot melt adhesive layer and a release paper on one side of a base material by overlapping the release paper so as to cover the hot melt adhesive.

According to this manufacturing method, when the hot melt adhesive is transferred to the nonwoven fabric, a portion of the hot melt adhesive enters the gaps between the fibers that make up the nonwoven fabric, thereby integrating the nonwoven fabric and the adhesive layer. It is thought that then.

Japanese Patent No. 6178291

In the manufacturing method of Patent Document 1, when a hot melt adhesive is transferred to a base material made of a nonwoven fabric, the amount of part of the hot melt adhesive that penetrates into the gap between the nonwoven fabrics is not constant, and as a result, the adhesive There is a problem in that the thickness of the layer exposed to the base material becomes uneven depending on the location and becomes inappropriate. In the case of a filter that is attached to an object such as a vent with an adhesive layer, if the thickness of the exposed part of the adhesive layer is not appropriate, gaps may easily form between the filter and the object, which may impair the collection performance. , there is a risk that it may become easily removed from the object.

Therefore, an object of the present invention is to provide a manufacturing method and a manufacturing apparatus that can provide a breathable product including a pressure-sensitive adhesive layer with an appropriate layer thickness at the portion exposed to the surface of a breathable base material.

In order to achieve the above object, a method for manufacturing a breathable product according to a first aspect of the present invention is a method for manufacturing a breathable product, the method comprising: preparing a breathable base material having a gap on at least one side. In the base material preparation process, an adhesive layer to be formed on a part of one side is prepared, and the hardness of the adhesive layer is adjusted so that only a part of this adhesive layer penetrates into the gap in the breathable base material. The method includes a hardness adjustment step of adjusting the hardness, and a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable base material.

With this configuration, by pressing the adhesive layer whose hardness has been adjusted against the air-permeable base material, only a portion of the adhesive layer enters the gap between the air-permeable base materials, and the two are integrated.

The method for manufacturing a breathable product according to the second aspect of the present invention is such that, in the configuration of the first aspect of the invention, the hardness adjustment step is performed on the opposite side of the pressure-sensitive adhesive layer from the side that is pressed against the breathable base material. The method includes a hardness increasing step of increasing the hardness of a region including the surface.

With this configuration, a difference in hardness occurs in the thickness direction in the adhesive layer.

In the method for manufacturing a breathable product according to the third aspect of the invention, in the configuration of the invention according to the second aspect, the adhesive layer is made of a hot melt adhesive, and the hardness increasing step is performed in the adhesive layer in a softened state. It includes a cooling step of cooling the area.

With this configuration, since the adhesive is a hot melt adhesive, the hardness of the cooled region of the adhesive layer increases.

A method for producing a breathable product according to a fourth aspect of the present invention is a method for manufacturing a breathable product according to the third aspect of the invention, in which the cooling step includes a mold release process in which an adhesive layer made of a softened hot melt adhesive is formed on one side. This method includes the steps of preparing a sheet and cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed.

With this configuration, since the surface of the release sheet opposite to the surface on which the adhesive layer is formed is cooled, the hardness of the region of the adhesive layer close to the release sheet increases. Since the surface of the adhesive layer is molded with a release sheet, it becomes flush and smooth.

A method for producing a breathable product according to a fifth aspect of the present invention is such that in the configuration of the fourth aspect of the invention, the step of cooling the release sheet includes releasing the metal roll at a temperature lower than the temperature of the adhesive layer. This includes the step of engaging the seat.

With this configuration, by engaging the low-temperature metal roll with the release sheet, the temperature of the adhesive layer in the vicinity of the release sheet decreases, and the hardness increases.

A method for manufacturing a breathable product according to a sixth aspect of the present invention is such that, in the configuration of the invention according to any one of the first to fifth aspects, the breathable base material is made of a nonwoven fabric.

With this structure, by pressing the adhesive layer against the breathable base material, a part of the adhesive layer invades the gaps between the fibers of the nonwoven fabric that constitutes the breathable base material, and after curing, the adhesive layer is pressed against the breathable base material. The material and the adhesive layer are integrated.

A method for manufacturing a breathable product according to a seventh aspect of the present invention is a method of manufacturing a breathable product according to any one of the first to sixth aspects, wherein the breathable product is a filter.

With this configuration, a filter product is produced that includes an adhesive layer with an appropriate layer thickness at the portion exposed to the surface of the air-permeable base material.

A method for manufacturing a breathable product according to an eighth aspect of the present invention is a method of manufacturing a breathable product according to any one of the third to fifth aspects, wherein the breathable product is an electrostatic filter.

With this configuration, an electrostatic filter including an adhesive layer made of a hot melt adhesive is manufactured.

A manufacturing apparatus for a breathable product according to a ninth aspect of the present invention is a manufacturing apparatus for manufacturing a breathable product in which an adhesive layer is formed on a part of one side of a breathable base material, A base material supply means for supplying an air permeable base material having a gap on the side, a release sheet supply means for supplying a release sheet, an adhesive supply means for supplying an adhesive, and an adhesive supply means for supplying a release sheet. an adhesive application means for forming an adhesive layer by applying an adhesive supplied from the agent supply means to a part of one side of a release sheet supplied from the release sheet supply means; a hardness adjusting means for adjusting the hardness of the adhesive layer so that only a part of the adhesive layer formed by the means penetrates into the gap in the air permeable base material; and a breathable base supplied from the base material supply means. and a pressing means for pressing the material against the adhesive layer having adjusted hardness.

With this configuration, the hardness of the adhesive layer applied to the release sheet by the adhesive coating means is adjusted by the hardness adjusting means, and then the air permeable base material is pressed against the adhesive layer by the pressing means to improve the air permeability. It is possible to manufacture a breathable product with an integrated structure by laminating an adhesive layer and a release sheet on one side of a base material and allowing a portion of the adhesive layer to penetrate into the gap in the breathable base material. It becomes a manufacturing device.

The apparatus for manufacturing a breathable product according to a tenth aspect of the present invention is such that, in the structure of the invention according to the ninth aspect, the adhesive is a hot melt adhesive, and the hardness adjusting means is a releasing mold on which the adhesive layer is formed. It includes a metal roll that engages the sheet and cools the release sheet.

With this configuration, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the adhesive layer is formed.

As explained above, in the method for manufacturing a breathable product according to the first aspect of the present invention, since the pressure-sensitive adhesive layer with adjusted hardness is pressed against the breathable base material, the pressure-sensitive adhesive layer penetrates into the breathable base material. The range can be adjusted. As a result, it is possible to obtain a breathable product in which the layer thickness of the portion exposed to the surface of the adhesive layer is optimized. Further, since a portion of the adhesive layer enters the gap in the air-permeable base material, the two become integrated after curing and increase the bonding strength, so that it is possible to suppress the adhesive residue when peeling off from the object to be attached.

In addition to the effects of the invention in the first aspect, the method for manufacturing a breathable product according to the second aspect of the invention is such that the adhesive layer has breathable properties by adjusting the hardness difference in the thickness direction of the adhesive layer. The ratio of the portion that penetrates into the substrate and the portion that is exposed to the surface of the breathable air substrate can be controlled.

In addition to the effects of the invention according to the second aspect, the method for manufacturing a breathable product according to the third aspect of the present invention provides a method for increasing the hardness of the adhesive layer by controlling the cooling temperature, cooling time, etc. Can be adjusted. Therefore, the layer thickness of the exposed portion of the adhesive layer can be easily adjusted to an appropriate thickness by simple processing.

In addition to the effects of the invention according to the third aspect, the method for manufacturing a breathable product according to the fourth aspect of the present invention cools the adhesive layer through a release sheet, so cooling is performed using a simple cooling means. Able to execute processes. Since the release sheet makes the surface of the adhesive layer flush and smooth, a breathable product that can be easily attached to an object can be obtained.

In addition to the effects of the invention according to the fourth aspect, the method for manufacturing a breathable product according to the fifth aspect of the present invention provides a method for producing a breathable product, since the metal roll can have a large heat capacity and high thermal conductivity. By bringing it into contact with the mold sheet, the hardness of a part of the adhesive layer can be increased in a short time. Therefore, it is possible to speed up the curing process of the adhesive layer, thereby increasing the manufacturing efficiency of breathable products.

In addition to the effects of the invention in any of the first to fifth aspects, the method for manufacturing a breathable product according to the sixth aspect of the present invention provides a method of manufacturing a breathable product by adjusting the hardness of the adhesive layer in advance, and then forming the adhesive layer. Since the pressure sensitive adhesive layer is pressed against the breathable base material, the layer thickness of the exposed portion of the adhesive layer can be made almost uniform even if the layer thickness is a non-woven fabric that tends to be uneven.

In addition to the effects of the invention in any of the first to sixth aspects, the method for manufacturing a breathable product according to the seventh aspect of the present invention is characterized in that the thickness of the exposed portion of the adhesive layer is appropriate. , it is possible to manufacture filter products that can be attached to objects such as vents without any gaps.

In addition to the effects of the invention according to any of the third to fifth aspects, the method for manufacturing a breathable product according to the eighth aspect of the invention includes forming the adhesive layer of the electrostatic filter with a hot melt adhesive. As a result, the deterioration of electrostatic function that occurs when the adhesive layer is formed using conventional solvent-based adhesives is suppressed, and we manufacture electrostatic filter products that have excellent collection efficiency for ultrafine particles such as PM2.5. can do.

In the apparatus for producing a breathable product according to the ninth aspect of the present invention, the thickness of the adhesive layer exposed on the surface of the breathable base material is appropriate, and the surface of the adhesive layer is flush with the release sheet. It is possible to provide a manufacturing apparatus that can manufacture smoothly molded breathable products.

In addition to the effects of the invention according to the ninth aspect, the apparatus for manufacturing a breathable product according to the tenth aspect of the present invention has a metal roll that has high thermal conductivity and a large size by appropriately setting the material and size. Since the release sheet can be provided with a heat capacity, by cooling the release sheet, it is possible to increase the hardness of the adhesive layer in the vicinity thereof in a short time. Further, by appropriately setting the size and rotation speed of the metal roll, the contact area and contact time with the release sheet can be controlled, and the range in which the hardness of the adhesive layer is increased can be easily adjusted. Therefore, by including such a metal roll, it is possible to realize a hardness adjusting means with a simple configuration and high control accuracy and reliability. In addition, since the metal roll allows the hardness adjustment process of the adhesive layer to be performed at high speed, it is possible to provide a manufacturing apparatus that can efficiently manufacture a breathable product in which the thickness of the exposed portion of the adhesive layer is uniform.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram showing an example of a breathable product according to an embodiment of the present invention, in which (A) is a partially omitted plan view, and (B) is a partially enlarged cross-sectional view of (A). 1 is a schematic diagram showing an example of a manufacturing apparatus for manufacturing a breathable product according to an embodiment of the present invention. FIG. 3 is an enlarged view of part A in FIG. 2; 4 is an enlarged sectional view taken along the line IV-IV in FIG. 3. FIG. FIG. 3 is an enlarged view of part B in FIG. 2; 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. 5. FIG. FIG. 3 is an enlarged view of section C in FIG. 2; 8 is an enlarged sectional view taken along line VIII-VIII in FIG. 7. FIG.

[Breathable products]
FIG. 1 is a diagram showing an example of a breathable product according to an embodiment of the present invention, in which (A) is a partially omitted plan view, and (B) is a partially enlarged cross-sectional view of (A). It is.

Referring to the figure, the breathable product F produced according to the present invention is, for example, a filter that is attached to an object to filter passing gas, and has a breathable product F that has a gap on at least one side. It includes a base material S1 and an adhesive layer N formed on a part of one side of the breathable base material S1. Further, in this example, a release sheet S2 disposed on the surface side of this adhesive layer N is included. A portion of the adhesive layer N has invaded the gap in the air-permeable base material S1.

A nonwoven fabric, a woven fabric, a knitted fabric, or a combination thereof is used for the breathable base material S1. As the material of the breathable base material S1, polypropylene or a copolymer mainly composed of propylene is often used. Further, for the purpose of imparting flame retardancy, etc., an appropriate amount of a fatty acid metal salt such as aluminum stearate may be added to the synthetic resin raw material, or flame retardant fibers may be mixed therein.

When the breathable product F is a filter, the breathable base material S1 preferably has a thickness of 0.3 to 15.0 mm and a basis weight of 20 to 200 g/m ² . With this configuration, it is possible to reliably collect dust in the air while allowing gas to pass through, and it also has practical strength. If the thickness is less than 0.3 mm or the basis weight is less than 20 to 200 g/m ² , practical strength may be insufficient and a sufficient collection function may not be exhibited. When the thickness exceeds 15.0 mm or the basis weight exceeds 200 g/m ² , gas flow resistance becomes large and the practicality as an air filter may be impaired.

For the adhesive layer N, it is preferable to use a solvent-free adhesive such as a hot melt adhesive or an emulsion adhesive.

As the hot melt adhesive, conventionally known hot melt adhesives can be used. Specifically, hot melt adhesives such as ethylene vinyl acetate type, polyolefin type, polyamide type, synthetic rubber type, acrylic type, polyurethane type, etc. Examples include adhesives. Among the above, for filters, it is preferable to employ synthetic rubber hot melt adhesives in consideration of the holding power when pasted on objects such as vents, the difficulty in leaving adhesive residue, etc.

When a synthetic rubber-based hot melt adhesive is used as a hot melt adhesive, examples of the synthetic rubber components contained therein include styrene-butadiene block copolymers, styrene-isoprene block copolymers, and block copolymers thereof. Examples include styrene elastomers such as hydrogenated products of polyisobutylene, butyl rubber (isobutylene-isoprene copolymers and modified products of these polymers), olefin elastomers such as polybutene, polychloroprene, nitrile rubber, and the like. By functioning as an elastomer, these synthetic rubber components can improve the cohesive force of the adhesive and, in turn, improve the adhesive force.

The hot melt adhesive can also contain one or more of the components listed below.
- Tackifier resins such as rosin resins, terpene resins, (hydrogenated) petroleum resins, coumaron-indene resins, hydrogenated aromatic copolymers, styrene resins, phenolic resins, xylene resins;
・Phthalate ester, adipate ester, sebacate ester, other fatty acid ester paraffin, epoxy polymer plasticizer, phosphate ester, phosphite ester, acrylic oligomer, polyisoprene, process oil, naphthenic oil, polyester Plasticizers such as polyols, polyether polyols, polyol compounds;
・Other polymers such as ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, polyvinyl acetate, etc. The above components may be used alone or in combination of two or more. You may also use it. These act as tackifiers for the adhesive and have the function of improving the adhesiveness (adhesion) of the adhesive to the breathable substrate.

In addition to the above components, other components that may be included in the hot melt adhesive include mineral oils (synthetic oils) such as petroleum hydrocarbons, vegetable oils, animal oils, paraffins, terpenoids, fatty acids, One type or a combination of two or more types of fatty acid esters, alcohols, honey, crotamiton, etc. can be used. All of these components act as softeners for the adhesive and have the function of preventing the adhesive strength of the adhesive from decreasing at low temperatures.

Moreover, the above-mentioned components also have the function of improving the coating suitability of the adhesive. For example, depending on the type, molecular weight, content, etc. of the elastomer component constituting the synthetic rubber hot-melt adhesive, stringiness may occur during application of the adhesive. In such a case, by adding a softener to the adhesive, stringing and the like can be suitably prevented and good coating suitability can be exhibited. Furthermore, by including the above-mentioned components in the adhesive, when the electrostatic filter structure of the present invention is peeled off from an object such as a vent after use, there is no residue of the hot melt adhesive on the object, that is, adhesive residue. can be suppressed.

The release sheet S2 is made of a thin sheet-like material that can hold the applied adhesive on the surface without absorbing it and also has good releasability to the adhesive. Examples of such materials include polyester films such as polyethylene terephthalate (PET) films, and polyolefin films such as polypropylene (PP) films.The surfaces of these films are coated with silicone resin or the like to improve releasability. A release agent may be applied.
[Manufacturing equipment]
Next, a manufacturing apparatus for manufacturing a breathable product according to the present invention will be explained.

FIG. 2 is a schematic diagram showing an example of a manufacturing apparatus for manufacturing a breathable product according to an embodiment of the present invention.

Referring to the figure, the manufacturing apparatus P of the present invention includes a base material supply means for supplying a breathable base material S1, a release sheet supply means for supplying a release sheet S2, and an adhesive M and an adhesive supplying means for supplying the adhesive, and applying the adhesive M supplied from the adhesive supplying means to a part of one side of the release sheet S2 supplied from the release sheet supplying means to form an adhesive layer. , a hardness adjusting means for adjusting the hardness of the adhesive layer so that only a part of the adhesive layer penetrates into the gap of the breathable base material S1, and a base material supplying means Pressing means for pressing the breathable base material S1 supplied from the pressure-sensitive adhesive layer of adjusted hardness.

In this example, for example, the breathable base material S1 is a nonwoven fabric, the release sheet S2 is a PET film, and the adhesive M is a hot melt adhesive that is hardened at room temperature and softens when heated. .

In addition, in the manufacturing apparatus P of this example, the supply means for the breathable base material S1 transports the breathable base material S1 with supply rolls 10 and 11 for supplying the breathable base material S1 while adjusting the transport speed. It is equipped with transport rolls 12, 13 and 14. The supply means for the adhesive M includes an adhesive supply roll 2 and an auxiliary roll 1 for feeding the adhesive M while storing it. The adhesive application means includes an application roll 3 and a backup roll 4 for applying the adhesive M supplied from the adhesive supply roll 2 to form an adhesive layer N in a predetermined pattern. The hardness adjustment means includes a metal roll 7 that is in contact with the surface of the release sheet S2 opposite to the surface on which the adhesive layer N is formed. The pressing means laminates and presses the breathable base material S1 supplied from the breathable base material supply means and the release sheet S2 whose adhesive layer has adjusted hardness to bond them together. It is equipped with nip rolls 5 and 6. Note that a known mechanism can be used as a supply means for the release sheet S2, and illustration thereof is omitted.

The auxiliary roll 1, the adhesive supply roll 2, the application roll 3, and the backup roll 4 are arranged adjacent to each other and are configured to rotate in conjunction with each other. A molten adhesive M is stored above the butt portion of the adhesive supply roll 2 and the auxiliary roll 1. When the adhesive supply roll 2 is rotated, the adhesive M adhering to its surface is transferred to the surface of the application roll 3 in contact with it. The transfer amount of the adhesive M can be controlled by adjusting the gap size between the adhesive supply roll 2 and the auxiliary roll 1.

As the coating roll 3, a known printing roll such as a gravure roll or a letterpress roll can be used. In addition, by making the surface of the application roll 3 a metal surface, releasability is improved, and the transfer of the adhesive M from the application roll 3 to the release sheet S2 is made smooth.

When the release sheet S2 is passed between the application roll 3 and the backup roll 4, the surface of which has been adhered to the adhesive M transferred from the adhesive supply roll 2, the adhesive M is applied to one side of the release sheet S2. Then, the adhesive layer N can be formed. The adhesive layer N can also be in the form of letters, designs, or the like.

The metal roll 7 that is brought into contact with the surface of the release sheet S2 opposite to the surface on which the adhesive layer N is formed is made of a metal with high thermal conductivity such as copper, brass, aluminum, iron, stainless steel, etc. . The heat capacity can be set by appropriately selecting the material and external dimensions. The contact area between the metal roll 7 and the release sheet S2 can be set by the diameter of the metal roll 7, the position of the metal roll 7 with respect to the path of the release sheet S2, and the like. The metal roll 7 may be provided with an appropriate heat dissipation mechanism or cooling mechanism. Note that the metal roll 7 can also have a tensor function that applies tension to the release sheet.
[Production method]
Next, a method for manufacturing a breathable product according to the present invention using the manufacturing apparatus P described above will be explained.

FIG. 3 is an enlarged view of section A in FIG. 2. As shown in FIG. FIG. 4 is an enlarged sectional view taken along line IV-IV in FIG. 3. FIG. 5 is an enlarged view of section B in FIG. 2. FIG. FIG. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. FIG. 7 is an enlarged view of section C in FIG. FIG. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG.

Referring to these figures, the manufacturing method of the present invention includes a base material preparation step of preparing a breathable base material S1 having a gap on at least one side, and an adhesive to be formed on a part of the one side. In addition to preparing the adhesive layer, there is a hardness adjustment step of adjusting the hardness of the adhesive layer so that only a part of the adhesive layer penetrates into the gap in the breathable base material S1, and the adhesive layer having the adjusted hardness is ventilated. and a pressing step of pressing the adhesive base material S1.

In this example, the base material preparation step is performed by means for supplying the breathable base material S1. The step of preparing the adhesive layer is carried out by applying the adhesive M to one side of the release sheet S2 using the application roll 3. The hardness adjustment step is carried out by bringing the metal roll 7 into contact with the opposite surface of the release sheet S2 on which the adhesive layer is formed. The pressing step is carried out by passing the surface of the release sheet S2 on which the adhesive layer is formed and the breathable base material S1 between nip rolls 5 and 6 in a state where they face each other.

The details of the manufacturing method of the breathable product F in this example will be described below.

Referring to FIG. 2, in the manufacturing apparatus P, by rotating the adhesive supply roll 2, the molten adhesive M stored in the upper part of the abutting portion of the adhesive supply roll 2 and the auxiliary roll 1 becomes sticky. It moves to the surface of the application roll 3 that is in contact with the agent supply roll 2.

Then, as shown in FIG. 3, by passing the release sheet S2 supplied from the supply means between the applicator roll 3 and the backup roll 4, the adhesive is applied to one side of the release sheet S2 in a predetermined pattern. M is applied, and as shown in FIG. 4, an adhesive layer N having a predetermined pattern is formed on the release sheet S2.

Next, the release sheet S2 on which the adhesive layer N is formed is conveyed to the position of the metal roll 7, and as shown in FIG. engage with. The metal roll 7 has a temperature lower than that of the adhesive layer N, has excellent thermal conductivity, and is configured to have sufficient heat capacity. Therefore, as shown in FIG. 6, since the adhesive layer N in a softened state on the release sheet S2 is cooled by the metal roll 7 via the release sheet S2, the release sheet A region near S2 becomes a hardness increasing region N1 in which the hardness is increased due to a decrease in temperature. On the other hand, the surface side region of the adhesive layer N away from the release sheet S2 is maintained in a softened state region N2 having fluidity.

Since the contact between the release sheet S2 and the metal roll 7 is substantially uniform in all parts, it is considered that the temperature of the adhesive layer N brought about by this contact is reduced substantially uniformly. Therefore, the layer thickness of the increased hardness region N1 in the adhesive layer N is made substantially uniform.

In addition, in FIG. 6, for convenience of explanation, the boundary between two areas, the increased hardness area N1 and the softened state area N2, is shown by a broken line, but in reality, the area near the release sheet S2 in the adhesive layer N is The hardness continuously changes from the pressure-sensitive adhesive layer N to the surface side region away from the release sheet S2.

In addition, since the degree and range of increase in hardness of the adhesive layer N can be controlled by adjusting the temperature, thermal conductivity, heat capacity, contact area and contact time of the metal roll 7 with the release sheet S2, the hardness It is possible to easily adjust the layer thickness of the increased region N1.

The release sheet S2, on which the hardness adjustment process of the adhesive layer N has been carried out in this manner, is conveyed to the positions of the nip rolls 5 and 6. On the other hand, the breathable base material S1 is also conveyed to the positions of the nip rolls 5 and 6 by supply rolls 10 and 11 and conveyance rolls 12, 13 and 14. At this time, the conveyance speeds of the breathable base material S1 and the release sheet S2 are controlled so as to match at the positions of the nip rolls 5 and 6.

As shown in FIG. 7, the air permeable base material S1 and the release sheet S2 supplied to the nip rolls 5 and 6 are arranged so that the air permeable base material S1 faces the surface on which the adhesive layer N of the release sheet S2 is formed. In this state, both are passed between nip rolls 5 and 6. Thereby, the adhesive layer N on the release sheet S2 is pressed against the breathable base material S1, and a breathable product F in which both are integrated is manufactured.

When the adhesive layer N is pressed onto the air-permeable base material S1, as shown in FIG. to invade. On the other hand, the increased hardness region N1 in the adhesive layer N near the release sheet S2 has low fluidity and therefore does not penetrate into the gap inside the breathable base material S1 and remains on the surface of the breathable base material S1.

The portion of the adhesive layer N that has penetrated into the air-permeable base material S1 forms an anchor layer R after curing, and exhibits excellent bonding strength to the adhesive layer N. Therefore, when the release sheet S2 is peeled off when the product is used, there is no risk of adhesive residue remaining on the surface of the release sheet S2 that causes the adhesive layer N to remain.

On the other hand, the increased hardness region N1 of the adhesive layer N forms an exposed layer Q exposed on the surface of the breathable base material S1 after curing. By adjusting the layer thickness of the increased hardness region N1 to be approximately constant, the exposed layer Q can also be formed to have an appropriate and approximately uniform layer thickness. This makes it difficult to create a gap between the breathable product F and the object when it is attached to the object. In addition, if the viscosity of the softened region N2, which is the part of the adhesive layer N that penetrates into the air permeable base material S1, is considerably low or the voids in the breathable base material S1 are large, the softened state region N2 may be removed before it hardens. The pressure-sensitive adhesive layer N may penetrate into the voids of the air-permeable base material S1 more than expected and even penetrate to the surface of the breathable base material S1 opposite to the surface on which the exposed layer Q is formed. When such permeation occurs, the breathable base material S1 is laminated and pressed and passed between the nip rolls 5 and 6 for bonding them together. The permeated adhesive layer N sticks to the nip roll 6 and the laminate of the breathable base material S1 and release sheet S2 wraps around the nip roll 6, or only the breathable base material S1 sticks to the nip roll 6 and is pulled, causing ventilation. Problems such as separation of the laminate of the air-permeable base material S1 and release sheet S2, or tearing of the air-permeable base material S1 due to part of the air-permeable base material S1 being pulled toward the nip roll 6 (see below) , the first problem) may occur. Furthermore, even if it passes between the nip rolls 5 and 6, if a transport roll (not shown) is used for transport to the next process, the adhesive layer N will stick to the nip roll 6 in the same way as before. A problem (hereinafter referred to as a second problem) may occur due to the air permeable base material S1 sticking. In order to prevent such first and second problems, it is necessary to soften the softened region N2 before the adhesive layer N penetrates to the surface opposite to the surface on which the exposed layer Q of the breathable base material S1 is formed. For this purpose, for example, for the first problem, a cooling mechanism may be provided on the nip roll 6 itself on the side that contacts the breathable base material S1, or for the second problem, a cooling mechanism may be provided. Alternatively, a cooling mechanism may be provided between the nip roll 6 and the conveyance roll for the next step to cool the surface of the air-permeable base material S1 opposite to the surface on which the exposed layer Q is formed. However, even when such a cooling mechanism is provided, the degree of cooling must be adjusted to prevent the adhesive layer N from penetrating into the air-permeable base material S1 and preventing the formation of the anchor layer R. It is preferable to perform balance adjustment.

The breathable product F produced as described above is cut into predetermined dimensions as necessary, manufactured into products, and sold as a filter product with a release sheet. In use, the release sheet S2 is peeled off at the work site, and the breathable base material S1 portion made of nonwoven fabric or the like is adhered to an object using the adhesive layer N.

In this example, the adhesive layer N is not formed on the entire surface of the breathable base material S1, but is formed partially by pattern coating. When the adhesive M is a hot melt adhesive, the preferred coating amount is 20 to 50 g/m ² , more preferably 25 to 35 g/m ² . Further, the preferred coating area of the hot melt adhesive is usually in the range of 40 to 80% of the entire air permeable substrate S1. However, the above numerical values may be changed as appropriate depending on the use and size of the breathable product F.
[Other embodiments]
Embodiments of the present invention are not limited to the above.

In addition to nonwoven fabric, woven fabric, knitted fabric, or a combination thereof may be used as the breathable base material.

As the adhesive, in addition to a hot melt adhesive, an emulsion adhesive, an ultraviolet curing adhesive, and the like can be used.

To adjust the hardness of the adhesive layer, in addition to the metal roll, a belt that moves at the same speed as the release sheet is brought into contact with the surface of the release sheet opposite to the side on which the adhesive layer is formed. It is conceivable to do so. Alternatively, it can also be performed by blowing cooling gas on the opposite side. When an ultraviolet curing adhesive is used for the adhesive layer, the hardness of the adhesive layer can be adjusted by irradiating the release sheet with ultraviolet rays from the side opposite to the side on which the adhesive layer is formed. Conceivable.

The adhesive supply means can also prepare a tank that stores the adhesive in a fluid state and supply the adhesive directly from this tank to the adhesive supply roll.

As the adhesive application means, in addition to a roll coating method using an application roll, a spray coating method, an inkjet method, a die coating method, a screen printing method, etc. can also be adopted.

The breathable products manufactured by the present invention can be installed in household equipment such as range hoods in kitchens and galleys, air conditioners, air purifiers, and ventilation fans, as well as indoor and outdoor vents and ventilation points in industrial equipment. It can be widely used as a constituent material of air filter products, masks, diapers, sheets, clothes, and other breathable sanitary products.

Note that the present invention can be applied to manufacturing an electrostatic filter. Electrostatic filters use electrostatic force to collect and remove fine particles in the air with high efficiency. Its use has expanded in recent years because it can effectively remove ultrafine particles called PM2.5, which have a diameter of 2.5 μm or less.

When manufacturing an electrostatic filter according to the present invention, a nonwoven fabric having an electrostatic effect is used as the breathable base material. Examples of such nonwoven fabrics include, for example, a combination of polyester fiber (PET fiber) and modacrylic fiber that has been subjected to a charging process, a polypropylene nonwoven fabric that has been subjected to a charging process using a corona discharge treatment, and a nonwoven fabric that includes wool fibers. The core-sheath type composite fiber, which is made of polypropylene resin whose surface is coated with polyethylene resin, is made by applying a DC high electric field to the core-sheath type composite fiber, which has been subjected to a tanning process after resin processing and a charging treatment. A known electrostatic filter, such as one whose surface is polarized and charged, can be used.

In addition, when manufacturing an electrostatic filter based on the present invention, by using a hot melt adhesive as an adhesive, ultrafine particles such as PM2.5 can be captured more effectively than when using a conventional solvent-based adhesive. The collection effect is improved.

The details of the mechanism by which the use of a hot melt adhesive improves the PM2.5 collection efficiency compared to the use of a conventional solvent-based adhesive are unknown. One hypothesis is that conventional adhesives are diluted with a solvent such as ethyl acetate, and when applied to an electrostatic filter, the adhesive and electrostatic filter may separate due to the flow during application. It is speculated that static electricity is generated at the interface or inside the adhesive, and this cancels out the charge on the electrostatic filter, reducing the PM2.5 collection efficiency of the electrostatic filter structure. Ru.

Therefore, based on the above speculation, the reason why the use of a hot melt adhesive improves the collection efficiency for PM2.5 is that the hot melt adhesive has a tendency to flow when pressed onto a breathable substrate. This is thought to be because static electricity is less likely to occur at the interface with the breathable base material or inside the adhesive layer since it does not contain a solvent.

In addition, the present invention can be applied in various ways and modified as appropriate depending on the implementation situation.

The present invention can manufacture a breathable product with a uniform thickness of the adhesive layer formed on a breathable base material such as a nonwoven fabric, so it can be installed on range hoods, air conditioners, air purifiers, ventilation fans, etc. It is possible to provide air filter products that are easy to attach to vents, etc. and have little adhesive residue, and constituent materials for sanitary products that have breathability.

In order to achieve the above object, a method for manufacturing a breathable product according to a first aspect of the present invention is a method for manufacturing a breathable product, the method comprising: preparing a breathable base material having a gap on at least one side. In the base material preparation process, an adhesive layer to be formed on a part of one side is prepared, and the hardness of the adhesive layer is adjusted so that only a part of this adhesive layer penetrates into the gap in the breathable base material. and a pressing step of pressing the adhesive layer with the adjusted hardness onto the breathable base material after the hardness adjustment process. a hardness increasing step of increasing the hardness of a region comprising a surface opposite to the side to be pressed, the adhesive layer of adjusted hardness is opposite to the side to be pressed to the breathable substrate; An increased hardness region is formed on the side surface, and the region of the side surface pressed against the breathable base material is maintained in a softened state region .

With this configuration, by pressing the adhesive layer whose hardness has been adjusted against the air-permeable base material, only a portion of the adhesive layer enters the gap between the air-permeable base materials, and the two are integrated. Further, a difference in hardness occurs in the thickness direction of the adhesive layer. Further, when the pressure-sensitive adhesive layer is pressed onto the breathable base material, the softened region invades into the voids of the breathable base material, whereas the increased hardness region does not invade into the voids inside the breathable base material.
A method for manufacturing a breathable product according to a second aspect of the present invention is a method for manufacturing a breathable product, which includes a base material preparation step of preparing a breathable base material having a gap on at least one side; A hardness adjustment step of preparing an adhesive layer to be formed on a part of the air-permeable base material and adjusting the hardness of the adhesive layer so that only a part of the adhesive layer penetrates into the gap in the air permeable base material; After the adjustment step, the pressure-sensitive adhesive layer with the adjusted hardness is pressed against the breathable base material, and the hardness adjustment step is performed on the opposite side of the pressure-sensitive adhesive layer to be pressed against the breathable base material. The method includes a hardness increasing step of increasing the hardness of a region including the side surface, the adhesive layer is made of a hot melt adhesive, and the hardness increasing step includes a cooling step of cooling the region of the adhesive layer in a softened state. In the cooling process, a release sheet is prepared with an adhesive layer made of a softened hot melt adhesive formed on one side, and the opposite side of the release sheet to the side on which the adhesive layer is formed is cooled. The pressing step includes a step of pressing the adhesive layer of the release sheet with adjusted hardness against the breathable base material to integrate the release sheet and the breathable base material.
With this configuration, by pressing the adhesive layer whose hardness has been adjusted against the air-permeable base material, only a portion of the adhesive layer enters the gap between the air-permeable base materials, and the two are integrated. Further, a difference in hardness occurs in the thickness direction of the adhesive layer. Furthermore, the release sheet and the breathable base material are integrated with the hardness of the adhesive layer adjusted to a certain layer thickness on the release sheet, and the surface of the adhesive layer is molded by the release sheet. This makes it flush and smooth.
In the method for manufacturing a breathable product according to the third aspect of the invention, in the structure of the invention according to the second aspect, the adhesive layer having the adjusted hardness is opposite to the side that is pressed against the breathable base material. An increased hardness region is formed on the side surface, and the region of the side surface pressed against the breathable base material is maintained in a softened state region.
With this configuration, when the adhesive layer is pressed onto the breathable base material, the softened region will enter into the voids in the breathable base material, whereas the hardened region will enter the void inside the breathable base material. Don't invade.
In the method for manufacturing a breathable product according to the fourth aspect of the present invention, in the structure of the invention according to the first aspect or the third aspect, the adhesive layer with adjusted hardness has adhesiveness from the hardness increasing region to the softening state region. The hardness of the agent layer changes continuously in the layer direction.
With this configuration, the layer thickness in the increased hardness region is made uniform.

In the method for producing a breathable product according to the fifth aspect of the invention, in the structure of the invention according to the first aspect, the adhesive layer is made of a hot melt adhesive, and the hardness increasing step is performed in the adhesive layer in a softened state. It includes a cooling step of cooling the area.

A method for producing a breathable product according to a sixth aspect of the present invention is a method for manufacturing a breathable product according to the fifth aspect of the invention, in which the cooling step includes a mold release process in which an adhesive layer made of a softened hot melt adhesive is formed on one side. This method includes the steps of preparing a sheet and cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed.

A method for producing a breathable product according to a seventh aspect of the present invention is a method according to the second aspect or the sixth aspect of the invention, in which the step of cooling the release sheet is lower than the temperature of the adhesive layer in the release sheet. The method also includes the step of engaging a cold metal roll with a release sheet.

In the method for manufacturing a breathable product according to an eighth aspect of the present invention, in the configuration of the invention according to any one of the first to seventh aspects, the breathable base material is made of a nonwoven fabric.

A method for manufacturing a breathable product according to a ninth aspect of the present invention is a method of manufacturing a breathable product according to any one of the first to eighth aspects, wherein the breathable product is a filter.

A method for manufacturing a breathable product according to a tenth aspect of the present invention is a method for manufacturing a breathable product according to any one of the second , third, fifth to seventh aspects, in which the breathable product is electrostatically charged. It is a filter.

A manufacturing apparatus for a breathable product according to an eleventh aspect of the present invention is a manufacturing apparatus for manufacturing a breathable product in which an adhesive layer is formed on a part of one side of a breathable base material, A base material supply means for supplying an air permeable base material having a gap on the side, a release sheet supply means for supplying a release sheet, an adhesive supply means for supplying an adhesive, and an adhesive supply means for supplying a release sheet. an adhesive application means for forming an adhesive layer by applying an adhesive supplied from the agent supply means to a part of one side of a release sheet supplied from the release sheet supply means; a hardness adjusting means for adjusting the hardness of the adhesive layer so that only a part of the adhesive layer formed by the means penetrates into the gap in the air permeable base material; and a breathable base supplied from the base material supply means. a pressure-sensitive adhesive layer having a hardness adjusted by the hardness-adjusting means , the hardness-adjusting means being opposite to the side of the adhesive layer that is pressed against the air-permeable base material. The adhesive layer with the adjusted hardness includes a hardness increasing means for increasing the hardness of the region including the side surface, and the hardness increasing region is formed on the surface opposite to the side surface pressed against the breathable base material. The region of the surface on the side pressed against the breathable base material is maintained in a softened state region .

With this configuration, the hardness of the adhesive layer applied to the release sheet by the adhesive coating means is adjusted by the hardness adjusting means, and then the air permeable base material is pressed against the adhesive layer by the pressing means to improve the air permeability. It is possible to manufacture a breathable product with an integrated structure by laminating an adhesive layer and a release sheet on one side of a base material and allowing a portion of the adhesive layer to penetrate into the gap in the breathable base material. It becomes a manufacturing device.
A manufacturing device for a breathable product according to a twelfth aspect of the present invention is a manufacturing device for manufacturing a breathable product in which an adhesive layer is formed on a part of one side of a breathable base material, A base material supply means for supplying an air permeable base material having a gap on the side, a release sheet supply means for supplying a release sheet, an adhesive supply means for supplying an adhesive, and an adhesive supply means for supplying a release sheet. an adhesive application means for forming an adhesive layer by applying an adhesive supplied from the agent supply means to a part of one side of a release sheet supplied from the release sheet supply means; a hardness adjusting means for adjusting the hardness of the adhesive layer so that only a part of the adhesive layer formed by the means penetrates into the gap in the air permeable base material; and a breathable base supplied from the base material supply means. The hardness adjustment means presses the material against the adhesive layer with hardness adjusted by the hardness adjustment means and integrates the release sheet and the breathable base material, and the hardness adjustment means controls the ventilation in the adhesive layer. The adhesive is a hot melt adhesive, and the hardness increasing means increases the hardness of a region including the surface opposite to the side that is pressed against the adhesive base material, the adhesive is a hot melt adhesive, and the hardness increasing means is a hot melt adhesive. It includes a cooling means for cooling the side opposite to the side on which the agent layer is formed.
With this configuration, the hardness of the adhesive layer applied to the release sheet by the adhesive coating means is adjusted by the hardness adjusting means, and then the air permeable base material is pressed against the adhesive layer by the pressing means to improve the air permeability. It is possible to manufacture a breathable product with an integrated structure by laminating an adhesive layer and a release sheet on one side of a base material and allowing a portion of the adhesive layer to penetrate into the gap in the breathable base material. It becomes a manufacturing device.

The apparatus for manufacturing a breathable product according to the first to third aspects of the present invention is the configuration of the invention according to the eleventh aspect, in which the adhesive is a hot melt adhesive, and the hardness adjustment means is a part of the adhesive layer formed on the adhesive layer. It includes a metal roll that engages the mold sheet and cools the release sheet.

With this configuration, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the adhesive layer is formed.
The apparatus for producing a breathable product according to a fourteenth aspect of the present invention is such that in the configuration of the invention according to the twelfth aspect, the cooling means includes a metal roll that engages with a release sheet on which an adhesive layer is formed. .
With this configuration, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the adhesive layer is formed.

As explained above, in the method for manufacturing a breathable product according to the first aspect of the present invention, since the pressure-sensitive adhesive layer with adjusted hardness is pressed against the breathable base material, the pressure-sensitive adhesive layer penetrates into the breathable base material. The range can be adjusted. As a result, it is possible to obtain a breathable product in which the layer thickness of the portion exposed to the surface of the adhesive layer is optimized. Further, since a portion of the adhesive layer enters the gap in the air-permeable base material, the two become integrated after curing and increase the bonding strength, so that it is possible to suppress the adhesive residue when peeling off from the object to be attached. Furthermore, by adjusting the hardness difference in the thickness direction of the adhesive layer, when the adhesive layer is pressed against the breathable base material, the softened region invades into the voids of the breathable base material. Since the hardness-increasing region does not penetrate into the gaps inside the breathable base material, it is possible to control the ratio of the portion of the adhesive layer that penetrates into the breathable base material and the portion exposed to the surface of the breathable base material.
In the method for manufacturing a breathable product according to the second aspect of the present invention, since the pressure-sensitive adhesive layer whose hardness has been adjusted is pressed against the breathable base material, the range of the pressure-sensitive adhesive layer that penetrates into the breathable base material can be adjusted. As a result, it is possible to obtain a breathable product in which the layer thickness of the portion exposed to the surface of the adhesive layer is optimized. Further, since a portion of the adhesive layer enters the gap in the air-permeable base material, the two become integrated after curing and increase the bonding strength, so that it is possible to suppress the adhesive residue when peeling off from the object to be attached. Furthermore, the release sheet and the breathable base material are integrated with the hardness of the adhesive layer adjusted to a certain layer thickness on the release sheet, and the surface of the adhesive layer is molded by the release sheet. Since it is flush and smooth, when the breathable product is attached to an object, it is difficult to create a gap between the breathable product and the object.
In addition to the effects of the invention according to the second aspect, the method for producing a breathable product according to the third aspect of the present invention provides adhesiveness to the breathable base material by adjusting the hardness difference in the thickness direction of the adhesive layer. When the adhesive layer is pressed, the softened region penetrates into the voids in the breathable base material, whereas the increased hardness region does not penetrate into the voids inside the breathable base material. It is possible to control the ratio of the part that penetrates into the air and the part that is exposed on the surface of the air permeable substrate.
In addition to the effects of the invention in the first aspect or the third aspect, the method for manufacturing a breathable product according to the fourth aspect of the present invention makes it possible to uniformize the layer thickness in the hardness increasing region. When attached to an object, it is difficult to create a gap between the object and the object.

In addition to the effects of the invention according to the first aspect, the method for manufacturing a breathable product according to the fifth aspect of the present invention provides a method for increasing the hardness of the adhesive layer by controlling the cooling temperature, cooling time, etc. Can be adjusted. Therefore, the layer thickness of the exposed portion of the adhesive layer can be easily adjusted to an appropriate thickness by simple processing.

In addition to the effects of the invention according to the fifth aspect, the method for manufacturing a breathable product according to the sixth aspect of the present invention cools the adhesive layer via a release sheet, so cooling is performed using a simple cooling means. Able to execute processes. Since the release sheet makes the surface of the adhesive layer flush and smooth, a breathable product that can be easily attached to an object can be obtained.

In addition to the effects of the invention according to the second or sixth aspect , the method for manufacturing a breathable product according to the seventh aspect of the invention can provide a metal roll with a large heat capacity and high thermal conductivity. By bringing this into contact with a release sheet, the hardness of a part of the adhesive layer can be increased in a short time. Therefore, it is possible to speed up the curing process of the adhesive layer, thereby increasing the manufacturing efficiency of breathable products.

In addition to the effects of the invention according to any one of the first to seventh aspects, the method for manufacturing a breathable product according to the eighth aspect of the present invention includes adjusting the hardness of the adhesive layer in advance and then forming the adhesive layer. Since the pressure sensitive adhesive layer is pressed against the breathable base material, the layer thickness of the exposed portion of the adhesive layer can be made almost uniform even if the layer thickness is a non-woven fabric that tends to be uneven.

In addition to the effects of the invention in any of the first to eighth aspects, the method for manufacturing a breathable product according to the ninth aspect of the present invention is characterized in that the thickness of the exposed portion of the adhesive layer is appropriate. , it is possible to manufacture filter products that can be attached to objects such as vents without any gaps.

The method for manufacturing a breathable product according to the tenth aspect of the present invention provides the effects of the invention according to any one of the second , third, fifth to seventh aspects, as well as the use of an electrostatic filter. Since the adhesive layer is formed with a hot melt adhesive, the deterioration of electrostatic function that occurs when the adhesive layer is formed with a conventional solvent-based adhesive is suppressed, and it is effective in collecting ultrafine particles such as PM2.5. It is possible to manufacture electrostatic filter products with excellent efficiency.

In the apparatus for producing a breathable product according to the eleventh aspect of the present invention, the thickness of the adhesive layer exposed on the surface of the breathable base material is appropriate, and the surface of the adhesive layer is flush with the release sheet. It is possible to provide a manufacturing apparatus that can manufacture smoothly molded breathable products.
In the air-permeable product manufacturing apparatus according to the twelfth aspect of the present invention, the thickness of the adhesive layer exposed on the surface of the air-permeable base material is appropriate, and the surface of the adhesive layer is flush with the release sheet. It is possible to provide a manufacturing apparatus that can manufacture smoothly molded breathable products.

In addition to the effects of the invention in the eleventh aspect, the apparatus for manufacturing a breathable product according to the first to third aspects of the present invention has a metal roll that has high thermal conductivity by appropriately setting the material and size. Since the release sheet can be provided with a large heat capacity, by cooling the release sheet, it is possible to increase the hardness of the adhesive layer in the vicinity of the release sheet in a short time. Further, by appropriately setting the size and rotation speed of the metal roll, the contact area and contact time with the release sheet can be controlled, and the range in which the hardness of the adhesive layer is increased can be easily adjusted. Therefore, by including such a metal roll, it is possible to realize a hardness adjusting means with a simple configuration and high control accuracy and reliability. In addition, since the metal roll allows the hardness adjustment process of the adhesive layer to be performed at high speed, it is possible to provide a manufacturing apparatus that can efficiently manufacture a breathable product in which the thickness of the exposed portion of the adhesive layer is uniform.
In addition to the effects of the invention in the twelfth aspect, the apparatus for manufacturing a breathable product according to the fourteenth aspect of the present invention has a metal roll that has high thermal conductivity and a large size by appropriately setting the material and size. Since the release sheet can be provided with a heat capacity, by cooling the release sheet, it is possible to increase the hardness of the adhesive layer in the vicinity thereof in a short time. Further, by appropriately setting the size and rotation speed of the metal roll, the contact area and contact time with the release sheet can be controlled, and the range in which the hardness of the adhesive layer is increased can be easily adjusted. Therefore, by including such a metal roll, it is possible to realize a hardness adjusting means with a simple configuration and high control accuracy and reliability. In addition, since the metal roll allows the hardness adjustment process of the adhesive layer to be performed at high speed, it is possible to provide a manufacturing apparatus that can efficiently manufacture a breathable product in which the thickness of the exposed portion of the adhesive layer is uniform.

Claims (10)

A method for producing a breathable product (F), comprising:
a base material preparation step of preparing a breathable base material (S1) having a gap on at least one side;
An adhesive layer (N) to be formed on a part of the one side is prepared, and the adhesive layer is formed so that only a part of the adhesive layer enters the gap of the breathable base material. a hardness adjustment step for adjusting the hardness;
and a pressing step of pressing the adhesive layer having the adjusted hardness onto the breathable base material. The air permeability according to claim 1, wherein the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the adhesive layer that includes a surface opposite to a side that is pressed against the air permeable base material. How the product is manufactured. The adhesive layer is made of a hot melt adhesive (M),
3. The method of manufacturing a breathable product according to claim 2, wherein the hardness increasing step includes a cooling step of cooling the region of the adhesive layer in a softened state. In the cooling step, a release sheet (S2) having an adhesive layer made of a softened hot melt adhesive formed on one side is prepared, and a release sheet (S2) is prepared on one side opposite to the side on which the adhesive layer is formed. The method for manufacturing a breathable product according to claim 3, comprising the step of cooling the side surface. 5. The method for producing a breathable product according to claim 4, wherein the step of cooling the release sheet includes a step of engaging the release sheet with a metal roll (7) having a temperature lower than that of the adhesive layer. The method for manufacturing a breathable product according to any one of claims 1 to 5, wherein the breathable base material is made of a nonwoven fabric. The method for manufacturing a breathable product according to any one of claims 1 to 6, wherein the breathable product is a filter. The method for manufacturing a breathable product according to any one of claims 3 to 5, wherein the breathable product is an electrostatic filter. A manufacturing apparatus (P) for manufacturing a breathable product in which an adhesive layer (N) is formed on a part of one side of a breathable base material (S1),
Base material supply means (10 to 14) for supplying a breathable base material having a gap on at least one side;
a release sheet supply means for supplying a release sheet (S2);
Adhesive supply means (1, 2) for supplying an adhesive (M);
adhesive application means (3) for applying the adhesive supplied from the adhesive supply means to a part of one side of the release sheet supplied from the release sheet supply means to form an adhesive layer; , 4) and
hardness adjusting means (7) for adjusting the hardness of the adhesive layer so that only a part of the adhesive layer formed by the adhesive applying means enters the gap of the breathable base material;
An apparatus for producing a breathable product, comprising pressing means (5, 6) for pressing the breathable base material supplied from the base material supply means onto the adhesive layer having the adjusted hardness. the adhesive is a hot melt adhesive,
The device for manufacturing a breathable product according to claim 9, wherein the hardness adjustment means includes a metal roll (7) that engages with the release sheet on which the adhesive layer is formed and cools the release sheet. .

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