JP2889731B2 - Polishing sheet and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a commercial or household disposable abrasive sheet and a method for producing the same.

[0002]

2. Description of the Related Art Generally, in order to remove dirt strongly adhered to the surface of metals, glass, ceramics, plastics, and the like, a powder cleanser or a liquid cleanser containing an abrasive is applied to a woven fabric, a nonwoven fabric, or a film material. Cleaning is performed by scraping off dirt. At that time, it is known to bond the abrasive by various methods in order to solve the trouble of attaching the abrasive to a nonwoven fabric, a sponge, or the like.
However, in these methods, there is a problem that the abrasive is easily dropped off and clogged easily unless washed frequently with water or the like.

On the other hand, Japanese Patent Application Laid-Open No. 51-1073 discloses a method in which a polishing agent is applied to a mesh to prevent the polishing powder from clogging and lowering the polishing effect. I have.

Japanese Patent Application Laid-Open No. Sho 56-104634 discloses that a net is laminated on the surface of a fine fiber layer.
A technique has been disclosed in which abrasive powder is captured by a fine fiber layer to reduce the influence on the surface to be cleaned.

Further, Japanese Patent Application Laid-Open No. 59-49728 discloses a cleaning sheet in which a thermoplastic mesh is laminated on the outer surface of a bulky fiber sheet.

[0006]

However, the method disclosed in Japanese Patent Application Laid-Open No. 51-1073 has a disadvantage that the discharged abrasive powder needs to be cleaned again, which is troublesome.

In the technique disclosed in Japanese Patent Application Laid-Open No. 56-104634, the mesh used for the surface layer is such that the abrasive powder captured by the fine fiber layer does not directly contact the surface to be cleaned or the human body. No positive polishing action by the mesh is given.

Further, in the technique disclosed in Japanese Patent Application Laid-Open No. 59-49728, the reticulated material is for preventing the bulky core layer from causing a lint phenomenon, and is provided with a positive polishing action. Not.

That is, there is a problem that the conventional technique cannot sufficiently remove dirt.

Accordingly, an object of the present invention is to provide a metal, glass,
An object of the present invention is to provide a polishing sheet capable of sufficiently removing dirt strongly adhered to the surface of pottery, plastic, or the like.

[0011]

SUMMARY OF THE INVENTION The present invention provides a base sheet comprising a heat-shrinkable base sheet and a non-woven fabric formed by entanglement of fibers, which is disposed in a layer on one or both sides of the base sheet. And a perforated sheet having a number of perforations formed outside the base fabric sheet, and the adjacent sheets are partially joined to each other to form a laminate, The above object has been achieved by providing a polishing sheet, wherein the cloth sheet and the aperture sheet have a concave shape at the joining portion, and the non-joining portion has a convex shape as a whole. Things.

The present invention also provides a method for suitably producing the above-mentioned abrasive sheet, in which a heat-shrinkable base sheet is provided in one or both sides of a heat-shrinkable base sheet in the form of a non-woven fabric formed by entanglement of fibers. After arranging the perforated sheet having a large number of perforations on the outside of the base fabric sheet, they are partially fused or adhered to join the adjacent sheets to each other, and then heated. A method for manufacturing a polishing sheet, wherein the base sheet is shrunk by a treatment so that a joint portion between the base fabric sheet and the aperture sheet is concave and a non-joined portion is entirely convex. Is what you do.

The shrinkable base sheet shrinks, the base cloth and the aperture sheet hardly shrink, and the base cloth and the aperture sheet are convex as a whole. The convex portion is polished, and then the polished dirt (polishing powder) is held by being entangled with the fibers of the base fabric. Further, the uneven shape allows the dirt to be effectively collected on the concave portion, so that clogging of the polished portion can be minimized. The polishing powder shown here refers to dirt removed by polishing. Further, dusts are also entangled in the nonwoven fabric as the base cloth. The dusts shown here are those having weak adhesion such as cotton dust existing on the surface to be cleaned.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the embodiments shown in FIGS.

As shown in FIGS. 1 and 2, a polishing sheet 10 according to an embodiment of the present invention is a heat-shrinkable base sheet 1.
1 and one or both sides of the base sheet (see FIG. 4)
A base cloth sheet 12 made of a nonwoven fabric formed by entanglement of fibers, and an aperture sheet 14 formed with openings 14A arranged outside the base cloth sheet, which are adjacent to each other. The sheets are partially joined to each other to form a laminated body 13A, and the base fabric sheet 12 and the aperture sheet 14 are formed in a concave shape in the joined portion, and the non-joined portions 13B and 15B are formed in a convex shape as a whole.

As the base sheet 11, for example, a heat-shrinkable film or a nonwoven fabric made of latently-crimpable fibers that exhibit crimpability by heat shrinkage and heating can be used. As the heat-shrinkable film, polyolefin-based, for example, polyethylene, polypropylene, polybutene, etc., polyester-based, for example, polyethylene terephthalate, polybutylene terephthalate, etc., and vinyl-based, vinylidene-based, for example, polyvinyl chloride, polyvinylidene chloride, etc. A film sheet of a polyamide-based resin or a modified product thereof, an alloy, a blend, or the like is preferable, and a film sheet that contracts in a uniaxial or biaxial direction according to a required uneven shape is appropriately selected. The thickness of the sheet needs to be determined in consideration of the contraction force, the shape and degree of irregularities depending on the contraction rate, the degree of partial workability with the nonwoven fabric, and the like. The resin of the sheet may be appropriately selected in consideration of the bonding property with the nonwoven fabric to be bonded.

As the base fabric sheet 12, a non-woven fabric formed basically by entanglement of fibers is used. As a method for forming a nonwoven fabric formed by entanglement of fibers, there are generally a needle punching method in which a fiber web is entangled with a needle and a water needling method in which a fiber web is entangled with a water flow. That is, the nonwoven fabric formed by entanglement of the fibers has a greater degree of freedom of the constituent fibers than the nonwoven fabric in which the fibers are only fused or bonded, and the entanglement retention between the stains and the fibers is extremely high. Therefore, the degree of fiber entanglement greatly affects the retention of dirt. That is, if the entanglement is too weak, the strength of the nonwoven fabric is significantly reduced, the workability is deteriorated, and the fibers are liable to fall off. The strength of the nonwoven fabric also changes depending on the type, physical properties, basis weight, and the like of the constituent fibers.

The types of fibers constituting the base fabric sheet 12 include thermoplastic fibers such as polyester-based, polyamide-based, and polyolefin-based fibers, composite fibers thereof, semi-synthetic fibers such as acetate, and regenerated fibers such as cupra and rayon. Any of natural fibers such as cotton and hemp may be used. Also, a cotton blend thereof may be used. However, in order to improve the bonding strength with the heat-shrinkable sheet, even if the fiber is basically entangled, it contains thermoplastic fibers and a part of the fibers is fused to increase the strength of the nonwoven fabric. May be performed as needed.

The basis weight of the base fabric sheet 12 may be determined by comprehensively considering the degree of entanglement, strength, workability, cost, and the like.
30 to 150 g / m ² is suitable. That is, if the basis weight is less than 30 g / m ² , it is difficult to obtain a necessary and sufficient degree of entanglement and strength, and if it is more than 150 g / m ² , it is disadvantageous in terms of cost. The fineness also affects the intertwining,
5-6.0 denier is suitable. If the thickness is less than 0.5 denier, the web formability becomes extremely poor, and if the thickness is more than 6.0 denier, the web is hardly entangled and the ability to catch dirt is deteriorated. Note that the base cloth sheet 12 may contain a surfactant or an oil agent in order to easily remove dirt adhered to the solid surface.

As the aperture sheet 14, a net or a perforated sheet made of a thermoplastic resin is used. As the resin used as the material, polyethylene, polypropylene, polybutene, etc., polyester-based, for example, polyethylene terephthalate, polybutylene terephthalate, etc., and vinyl-based, vinylidene-based, for example, polyvinyl chloride, polyvinylidene chloride, nylon, etc. The opening may be regular or irregular in the case of a polyamide resin or a modified product thereof, an alloy, a blend, or the like, but from the viewpoint of function, the distance between the holes is preferably 100 mm or less, and 1 mm or more. In addition, it is necessary that the aperture sheet 14 having the apertures 14A can capture the polished dirt on the base cloth. In particular, when a net is used, the polishing effect can be controlled by selecting the wire diameter and the material (hardness).

The hardness of the perforated sheet 14 is determined by the hardness of the perforated sheet 14 when used in a sink or range for home use.
Hardness is Rockwell hardness test (JIS Z-224)
In 5), it is preferable to use a resin having an R50 or more and M130 or less.

An abrasive may be applied to the aperture sheet 14 depending on the object to be polished. At that time, the abrasive includes all those used in conventionally known abrasives, for example, aluminum oxide, calcium carbonate, iron oxide, gemstone, zeolite, feldspar, talc, quartz, phosphorus lime, The examples include yellow stone, garnet, molten zirconia, silicon carbide, and boron carbide. In addition, in order to adhere the abrasive to the sheet having openings, a thermosetting resin, a binder obtained by dissolving a thermoplastic resin in a solvent, a commercially available adhesive, or the like, using a spray method, a dipping method, or the like. Just do it. However, it is preferable that the abrasive and the particle size be applied in various ways depending on the object.

Next, the joining with the base sheet 11, the base cloth sheet 12, and the aperture sheet 14 will be described. The resin material of the base sheet 11, the type of constituent fibers of the base cloth sheet 12, and the resin of the aperture sheet 14 may be selected from the above-mentioned ones according to the joining method.

The joining portion 13A and the non-joining portion 13B of the base cloth 12, the base sheet 11, and the opening sheet 14 form irregularities, and the joining portion 13A has a concave shape and the non-joining portions 13B and 15B have a convex shape. Have been. In addition, the joining portion 13A is formed in a lattice shape as shown in FIG.

In the base cloth 12, as shown in FIGS. 1 and 2, the non-joined portion 13B is formed as a convex portion 12A, and the joined portion 13A is formed as a concave portion 12B. The base cloth 12 has a large number of convex portions 12A.
And the concave portion 12B therebetween form a polished surface having cushioning properties. The polished surface is composed of entangled fibers, and fine dirt or the like attached to the surface to be polished is captured between these constituent fibers. At the same time, relatively large dirt is trapped by being sandwiched between the concave portions 12B.

The joining pattern 13A may be regular or irregular, but in terms of visual aesthetics and function, the distance between adjacent joining portions is preferably 3 to 100 mm. 3
If it is smaller than mm, the unevenness of the nonwoven fabric after shrinkage is not so much expressed, and if it is larger than 100 mm, one convexity becomes too large, and the unevenness per unit area of the nonwoven fabric is small, which is not preferable in terms of abrasiveness and appearance.

FIGS. 4 and 5 show a polishing sheet 30 according to a modified example in which the base cloth sheet 12 and the aperture sheet 14 are arranged on both sides of the base sheet 11, and FIGS. The same reference numerals are given to the same portions as those in the above-described embodiment shown in FIG.

Next, a preferred embodiment of the present invention for producing the polishing sheet 10 will be described together with its production apparatus.

As shown in FIGS. 1 and 2, the manufacturing apparatus 20 is configured to manufacture the polishing sheet 10 having the opening sheet 14 only on one side. That is, as shown in FIG. 7, the base sheet 11, the base cloth 12, and the opening sheet 14 are each configured to be unwound from a rolled state. Roll-shaped base cloth 12
Is unwound by the feeding device 21.

The base sheet 11 is unwound from the upper side by a guide roller 24A disposed on the downstream side, and is superposed on the conveyed base cloth 12. An opening sheet 14 is arranged below the base cloth 12 corresponding to the base sheet 11, and the base cloth 1 unwound from the lower side and conveyed by the guide rollers 24B.
It is designed to overlap with 2.

The base sheet 11 and the opening sheet 1 superposed on the base cloth 12 by the guide rollers 24A and 24B.
4 is joined in a grid pattern as shown in FIG. 1 by a joining machine 25 disposed downstream of the guide rollers 24A and 24B. The joining machine 25 includes a base cloth 12, a base sheet 11
The opening sheet 14 is ultrasonically welded.
That is, the joining machine 25 is provided with a horn 25 that oscillates ultrasonic waves.
A and an embossing roll 25B having a mold formed in a lattice-like pattern, while the superposed base cloth 12, base sheet 11 and opening sheet 14 pass, as shown in FIG. , 12 and 14 are joined to form a grid-like joint 13. The joining machine 25 is not limited to the ultrasonic method, but may be a heating method or the like. Such a method is appropriately selected depending on the processing speed and the selection of the material.

The integrated base cloth 12 and the base sheet 11 joined by the joining machine 25 are pulled out by a nip roll 26 disposed downstream of the joining machine 25 and delivered to a heat treatment device 27.

The heat treatment apparatus 27 is for heat-shrinking, and is formed as a heating chamber for heating the base sheet 11 to a temperature for heat-shrinking. Then, while the integrated base cloth 12, the base sheet 11, and the opening sheet 14 pass through the heat treatment device 27, only the base sheet 11 thermally shrinks at a non-joined portion surrounded by the lattice-like joined portion 13A. At the same time, a protruding portion 12A is formed on the
Is formed.

The polishing sheet 10 formed by passing through the heat treatment device 27 is pulled out by the nip rolls 28, 28 disposed downstream of the heat treatment device 27, and is taken up by the winder 2.
9, the polishing sheet 10 is wound as a winding roll.

Therefore, according to the present embodiment using the above-described manufacturing apparatus, the polishing sheet 10 is manufactured as follows.

That is, first, the base cloth 12 is
1, the base sheet 11 is supplied from above on the downstream side and the open sheet 14 is supplied from below on the downstream side, and are superposed by the guide rollers 24A and 24B. The base sheet 11, the base cloth 12, and the opening sheet 14 thus superimposed are joined to the joining machine 2
5 is pulled out by nip rolls 26, 26 in a state of being ultrasonically welded and joined and integrated, and heat treatment apparatus 2
Delivered to 7. In this state, the sheet is in a state as shown in FIG. 3 (FIG. 5 when the opening sheets 14 are arranged on both sides). With the integrated base sheet 11 and base cloth 12, only the base sheet 11 thermally shrinks while passing through the heat treatment device 27, and FIG. 2 (FIG. 4 when the opening sheets 14 are arranged on both sides). As shown in (1), a convex portion 12A is formed at the non-joined portion of the base cloth 12, and is formed as the polishing sheet 10. The polishing sheet 10 is made of nip rolls 28, 28.
Then, it is drawn out of the heat treatment device 27 and wound up as a winding roll 10 in a winder 29.

Hereinafter, the polishing sheet of the present invention will be described based on more specific examples.

Example 1 A 1.5-denier polyester fiber (51 mm) was formed into a web (basis weight: 100 g / m ² ) by a conventional card, and entangled with a water lead ring and a polyester net (5 mesh, A wire having a diameter of 0.5 mm and a hardness of M94) and a biaxially shrinkable polyester film of 40 μm were joined together by ultrasonic embossing in a 30 mm-diameter, 30 ° rhombic pattern to obtain a sheet of 20 cm × 20 cm. Thereafter, a heat treatment (condition: 130 ° C. × 30 seconds) was performed to obtain a polishing sheet of 18 cm × 18 cm.

Example 2 1.5 denier, 51 mm of polypropylene fiber and 1.5 denier, 51 mm of rayon fiber were mixed at a ratio of 50/50, and a web was formed with a conventional card (basis weight: 70 g / m ² ) and water was added. Base fabric entangled with a lead ring and polypropylene net (5 mesh, wire diameter 0.5 mm, hardness R90)
And a polypropylene biaxially shrinkable film of 30 μm were joined and integrated by ultrasonic embossing in a square pattern having a side of 20 mm to obtain a sheet of 20 cm × 20 cm. Thereafter, heat treatment (condition: 110 ° C. × 30 seconds) was performed to obtain a polishing sheet of 18 cm × 18 cm.

Comparative Example 1 A 1.5-denier polyester fiber (51 mm) was formed into a web (basic weight: 100 g / m ² ) using a conventional card, and entangled with a water lead ring to obtain an 18 cm × 18 cm polishing sheet. Obtained.

COMPARATIVE EXAMPLE 2 A 1.5-denier polyester fiber (51 mm) was formed into a web (basis weight: 100 g / m ² ) using a conventional card, and a biaxial shrink film of polyester and a base fabric entangled by a water lead ring was 40 μm. With ultrasonic embossing, 30mm on a side,
Joined and integrated in a 30 ° diamond pattern, 20cm x 20cm
Sheet was obtained. Then heat treatment (condition 130 ° C × 30)
Second) to obtain a polishing sheet of 18 cm × 18 cm.

COMPARATIVE EXAMPLE 3 A web of 1.5 denier and 51 mm of polyester fiber was formed with a conventional card (basis weight 100 g / m ² ) and entangled with a water lead ring and a polyester net (5 mesh, A wire having a diameter of 0.5 mm and a hardness of M94) was joined and integrated with a diamond pattern of 30 mm on a side and 30 ° by ultrasonic embossing to obtain a polishing sheet of 18 cm × 18 cm.

EXPERIMENTAL EXAMPLE The polishing sheets obtained in the above Examples and Comparative Examples were examined for their polishing effect on dirt, clogging, and trapping property. The results are shown in Table 1 below. The following dirt was used as the target dirt. (Dirt) iron (3cm
× 8 cm) of a rapeseed oil / carbon black (weight ratio: 5/1) mixture applied to a test piece of 0.06 g was denatured at 150 ° C. for 30 minutes to obtain a weakly modified stain (pencil hardness of 5).
B).

[0043]

[Table 1]

As is clear from Table 1, the polishing sheet according to the present embodiment exhibits excellent effects in terms of polishing effect, clogging, and trapping property, and has a wide range of dirt not found in the conventional polishing sheet. Can be cleaned. In this method, dirt strongly adhered to the solid surface is mainly polished with the outermost aperture sheet, and dust adhering due to relatively weak adhesion is trapped by entanglement with the fibers constituting the base fabric, and This is because the abrasive powder polished off by the apertured sheet of the outer layer is also captured by the base cloth.

[0045]

According to the polishing sheet of the present invention, it is possible to sufficiently remove dirt strongly adhered to the surface of metal, glass, pottery, plastic or the like.

Further, since the three-dimensional sheet improves the cushioning property and has a high ability to retain the abrasive powder obtained by polishing off the fixed dirt, there is no need to wash off or wipe twice after polishing. Further, according to the method of the present invention, a uniform polishing sheet can be stably produced at high speed.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a polishing sheet according to an embodiment of the present invention.

FIG. 2 is a sectional view showing the polishing sheet shown in FIG.

FIG. 3 is a cross-sectional view showing a state before heat treatment of the sheet shown in FIG.

FIG. 4 is a sectional view showing a polishing sheet according to a modification of the present invention.

5 is a cross-sectional view showing a state before heat treatment of the polishing sheet shown in FIG.

FIG. 6 is a schematic view showing an entire manufacturing apparatus suitably used for manufacturing the polishing sheet shown in FIG.

[Explanation of symbols]

 10, 30 Polishing sheet 11 Base sheet 12 Base cloth 12A Convex part 12B Concave part 14 Opening sheet

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI B32B 7/04 B32B 7/04 // C08J 5/14 C08J 5/14 B29L 7:00 9:00 (58) Field surveyed ( Int.Cl. ⁶ , DB name) A47L 13/00-13/62 B29C 61/02 B32B 3 / 24,5 / 26,7 / 02

Claims (4)

(57) [Claims] 1. A heat-shrinkable base sheet, a base cloth sheet made of a non-woven fabric formed by entanglement of fibers, disposed on one side or both sides of the base sheet, and an outer side of the base sheet Are arranged in a perforated sheet having a number of perforations formed thereon, and the adjacent sheets are partially joined to each other to form a laminate, and the base fabric sheet and the perforated sheet are A polishing sheet, wherein the joining portion has a concave shape, and the non-joining portion has a convex shape as a whole. 2. The polishing sheet according to claim 1, wherein the aperture sheet is a net made of a thermoplastic resin. 3. The polishing sheet according to claim 1, wherein the aperture sheet is a perforated film made of a thermoplastic resin. 4. A heat-shrinkable base sheet on one or both sides of which a base cloth sheet made of a nonwoven fabric formed by entanglement of fibers is arranged in layers, and the perforated sheet having a large number of perforations is formed on the base sheet. After being arranged on the outside of the base fabric sheet, these are partially fused or adhered to join the adjacent sheets to each other, and then the base sheet is contracted by a heat treatment, and the base fabric sheet and A method for manufacturing a polishing sheet, wherein a joining portion of the apertured sheet is concave and a non-joining portion is entirely convex.