JP2944719B2 - Method of manufacturing corrugated sheet - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a corrugated sheet using a difficult-to-form sheet such as a nonwoven fabric.

2. Description of the Related Art <Corrugated Cardboard> As is well known, a corrugated cardboard has a configuration in which a flat liner and a corrugated core are laminated and bonded. Types of cardboard include single-sided cardboard, double-sided cardboard, double-sided cardboard, double-sided cardboard, and the like. Cardboard is
It is manufactured with a device called a corrugator.

The liner is classified into a kraft liner (kraft valve 100%) and a jute liner (kraft pulp combined with waste paper pulp) depending on the type of pulp used.
The cores are roughly classified into SCP cores using semi-chemical pulp and special cores mainly composed of waste paper pulp, depending on the type of pulp used.

The corrugator includes a single facer, a double backer, and a cutter. Among them, the single facer includes a pair of upper and lower step rolls (an upper roll and a lower roll), a press roll, and a gluing roll. After the core supplied to the upper roll is stepped by meshing the upper roll and the lower roll, an adhesive is applied by a gluing roll provided next to the lower roll, and then pressed toward the lower roll. At the point of contact with the press roll, lamination bonding is performed with the liner supplied along the press roll.

<Corrugation of Sheet Containing Nonwoven Fabric> The following proposal has been made as a method of corrugating a sheet containing nonwoven fabric.

Japanese Utility Model Laid-Open No. 2-29718 discloses a rigid core (a metal foil or a plastics film) on both sides of which a paper is laminated and a nonwoven fabric laminated on at least one of the papers, and a hot melt film on one side. A corrugated cardboard laminate comprising laminated water-resistant liner paper, wherein the core and the water-resistant liner paper are welded with a hot melt film via a nonwoven fabric is shown.

Japanese Patent Publication No. 1-10331 (Japanese Patent Application Laid-Open No. 57-1711) discloses that a glass cloth substrate is impregnated with a resin as a member to be molded, and then an organic fiber nonwoven fabric is polymerized on both sides thereof to form a pressure roller. Prepare a bonded thing, in a mold composed of a metal plate that has a plurality of predetermined irregularities continuously and moves up and down,
Insert the above-mentioned molded member from one end thereof, heat and press by the first uneven portion to form a corrugated shape, then open both molds and adjoin the first molded corrugated portion to the next molded member There is shown a method in which an operation of feeding a concave and convex portion, closing a mold, and molding a next molded portion is repeated, and a corrugated portion is sequentially molded one by one.

Japanese Patent Application Laid-Open No. 62-140820 discloses that the upper and lower surfaces of a glass cloth substrate coated with an impregnated resin are irradiated with ultraviolet rays to make the impregnated resin on the surface part in a semi-cured state. A method of forming a corrugated shape by forming a member to be formed and passing the member to be formed between upper and lower mold rollers having uneven portions that mesh with each other is shown.

JP-A-57-170742 discloses that a card web is needle-punched to form a non-woven fabric, an adhesive is applied to the lower surface, a separately manufactured thick felt is bonded to and integrated with the non-woven fabric, and the resulting composite is obtained. A method is shown in which a corrugated shape is formed on the nonwoven fabric side of a material by a driving cylinder and a punch hammer.

JP-B-53-36060 (JP-A-51-35770) discloses a state in which a fiber material such as a yarn or a fabric is bent and arranged along a group of bars arranged in a line perpendicular to the traveling direction of the belt. Thus, there is disclosed a corrugated fixing method of a fibrous material in which a bonding film is placed on a group of bent portions and heated to be fixed and integrated.

Problems to be Solved by the Invention At present, nonwoven fabrics made of various materials and having various functions have been developed. If such a nonwoven fabric can be corrugated, it can be expected to have applications that have not been used before.

When manufacturing a corrugated sheet having a configuration in which a flat sheet and a step-formed sheet are laminated and bonded by a corrugator, when the step-formed sheet is paper, smooth step-forming can be performed even at a high speed.

However, if an attempt is made to use a difficult-to-form sheet such as a nonwoven fabric as the step forming sheet, the formability of the corrugator single facer at the time of stepping due to meshing between the upper roll and the lower roll of the single facer is insufficient, and the stepped nonwoven fabric is not used. Is inevitable to emerge from the groove of the lower roll. That is, since the mesh between the upper and lower step rolls is a short time that can be called even a moment, permanent deformation cannot be performed with the nonwoven fabric. Such troubles can be suppressed to some extent if the rotation speed of the step roll is extremely reduced, but it is still insufficient, and such an extremely low rotation rate of the step roll impairs industrial efficiency. Become like When a low-density nonwoven fabric is used as the step-formed sheet, the adhesive applied by the sizing roll may penetrate to the back surface of the nonwoven fabric and reach the lower roll, thereby contaminating the lower roll.

The present inventors have tried to corrugate using a nonwoven fabric as a step-formed sheet, but as described above, the nonwoven fabric has difficult-to-shape properties, so that it can be industrially adopted regardless of the laboratory. It was very difficult to reach the level.

In addition, not only the nonwoven fabric alone but also various methods for corrugating a sheet containing the nonwoven fabric have been proposed as described above, and these will be devised.

Japanese Unexamined Utility Model Publication No. Hei 2-29718 discloses a water-resistant core in which a rigid film is laminated with paper on both sides and a nonwoven fabric is laminated on at least one of the papers, and a hot melt film is laminated on one side. Lamination bonding is performed with liner paper. Therefore, although the nonwoven fabric is used, the core is not constituted only by the nonwoven fabric.

In Japanese Patent Publication No. 1-10331, a glass cloth base material is impregnated with a resin, and an organic fiber nonwoven fabric is polymerized on both sides thereof and bonded with a pressure roller as a molded member. The method of opening and closing the mold and sequentially forming the corrugated portion one by one is adopted. This method does not form a corrugated sheet only with a nonwoven fabric, nor does it involve the production of a corrugated sheet by a corrugator. In addition, the method of opening and closing a mold and sequentially forming a corrugated portion one by one is extremely efficient. Is bad.

In JP-A-62-140820, a heat-resistant polyamide non-woven fabric bonded to both surfaces of a glass cloth substrate via an ultraviolet-curable resin is used as a molded member, and only the non-woven fabric is corrugated. Not something.

JP-A-57-170742 discloses a method in which a corrugated sheet is formed by a corrugator using a corrugator, in which a corrugated sheet is formed by a cylinder and a punch hammer that are driven into the non-woven fabric side of an integrated product of a needle-punched non-woven fabric and a thick felt. It does not depend on.

The invention of Japanese Patent Publication No. 53-36060 also discloses a method of bending and arranging a fiber material such as a thread or a fabric along a group of bars arranged vertically, and fixing the corrugated sheet. This is not the case.

In view of such circumstances, an object of the present invention is to provide an industrial method for corrugating a difficult-to-form sheet such as a nonwoven fabric.

Means for Solving the Problems A method for producing a corrugated sheet of the present invention comprises a flat sheet (a) and a stepped sheet (b) using a corrugator.
When manufacturing a corrugated sheet having a configuration in which the flat sheet (a) and the step-formed sheet (b) are laminated and adhered, at least a step-forming sheet is used as the step-formed sheet (b), and a step-formed sheet is used. When supplying (b) to the upper roll of the single facer of the corrugator, the easily formable sheet (c) is applied from above the step-formed sheet (b), and the step-formed sheet (b) and the flat sheet (a) are applied. After laminating and adhering, the easily formable sheet (c) is peeled off and removed.

 Hereinafter, the present invention will be described in detail.

Prerequisites The present invention relates to a method for manufacturing a corrugated sheet having a configuration in which a flat sheet (a) and a step-formed sheet (b) are laminated and adhered by a corrugator.
Before describing the characteristic features of the present invention, this prerequisite will be described first.

The corrugated sheet has a configuration in which a flat sheet (a) and a step-formed sheet (b) are laminated and bonded. Examples of the laminated structure include (a) / (b), (a) / (b) / (a), (a) / (b) / (a) / (b) / (a), (a) / (B) / (a) / (b) / (a) / (b)
/ (A).

The flat sheet (a) corresponds to a cardboard liner,
The corrugated sheet (b) corresponds to the core of the corrugated cardboard, but in the present invention, a material other than paper may be used as the material corresponding to the base paper. In order to avoid confusion, the terms “flat sheet” and “step-formed sheet” are used, respectively.

The type of corrugation (flute), that is, the number of peaks per corrugation height and unit length, is the same as that for corrugated cardboard.
It may be a B flute, a C flute, an E flute, or the like.

Corrugated sheet (1) having the above laminated structure
Are manufactured using a corrugator.

As described in the section of the related art, the corrugator includes a single facer, a double backer, and a cutter.

Among them, the single facer is composed of a pair of upper and lower step rolls (upper roll and lower roll), a press roll and a gluing roll that mesh with each other, and as peripheral devices, a mill roll stand, a preheater for a flat sheet, a preheater for a step forming sheet, a glue It is equipped with glue pans.

A groove is provided in the lower roll in the circumferential direction, and a presser called a finger is provided in the groove to prevent the step forming sheet (b) from floating. The spacing between the fingers varies from flute to flute, and this is also not fixed by the roll manufacturer, but for example, 55mm, 65mm,
For example, 75 mm. Since the adhesive cannot be applied to the finger portion, the presence of the finger has a negative effect on the adhesion, but the finger is necessary to prevent the step-formed sheet (b) from floating. (There is also a method in which the fingers are omitted and the step-formed sheet (b) is brought into close contact with the lower roll side by vacuum suction, but this method is not appropriate when the sheet material has air permeability.) It is composed of a combination of glue rolls (applicator rolls and doctor rolls), glue machines consisting of rider rolls, heating sections consisting of hot plates, cotton belts, idler rolls, cleaning sections consisting of upper and lower belts and a pair of upper and lower idler rolls. , As peripheral devices,
Equipped with a mill roll stand, liner preheater, glue glue pan, etc.

The cutter is configured by, for example, a combination of a slitter scorer, a cutter, and the like.

For example, when manufacturing a corrugated sheet having the above-described laminated structure, first, a step-formed sheet (b) is formed at a single facer portion of a corrugator, and the sheet is bonded to a flat sheet (a). The laminated structure is such that the flat sheet (a) is adhered to the backer. In the above case, the number of single facers corresponding to that is used.

Examples of the adhesive used in the production of the corrugated sheet or the multi-stage structure thereof include corn starch, water-resistant corn starch, wheat starch, potato starch, modified starch, polyvinyl acetate emulsion, polyvinyl alcohol, polyvinyl butyral, polyethylene, and ethylene-vinyl acetate copolymer. Various water-soluble, water-dispersible, or hot-melt adhesives whose main component is coalesce, water glass, etc. are used.

Characteristic part In the present invention, a difficult-to-form sheet is used as at least the step-formed sheet (b) of the flat sheet (a) and the step-formed sheet (b). A typical example of the difficult-to-shape sheet is a nonwoven fabric made of organic or inorganic fibers. The nonwoven fabric may carry a drug, a resin, organic or inorganic particles, or the like. A sheet other than the nonwoven fabric can be used as long as it is difficult to shape. Since a sheet having good shapeability can be easily produced by conventional corrugating, it is needless to apply the method of the present invention.

As the flat sheet (a) which does not require the shaping property, an arbitrary sheet such as nonwoven fabric and paper is used. However, since a difficult-to-form sheet is used as the step-formed sheet (b), it is important from the viewpoint of application that the flat sheet (a) also uses a difficult-to-form sheet such as a nonwoven fabric.

In the present invention, when the step-formed sheet (b) is supplied to the upper roll of the single facer of the corrugator, the easy-to-form sheet (c) is placed on the step-formed sheet (b).
After the laminating and bonding of the step-formed sheet (b) and the flat sheet (a), the easily formable sheet (c) is peeled off.

At this time, as the easily formable sheet, paper such as pure white roll paper and kraft paper or cellophane is preferably used. The basis weight is suitably about 32 to 75 g / m ^2, but a liner used for conventional corrugated cardboard or one having a basis weight of about the core may be used.

The laminating speed at the time of corrugating is desirably smaller than that in the case of the conventional corrugated cardboard, and for example, about 5 to 50 m / min, preferably about 10 to 40 m / min is appropriate.

It is also desirable to reduce the finger spacing as compared to conventional cardboard manufacturing, for example, about 30 to 65 mm,
Preferably, about 35 to 50 mm is appropriate, but depending on the type of the easily shapeable sheet (c) and the laminating speed conditions, smooth corrugating can be performed even when the finger interval is 75 mm as in Example 2 described later. It is possible.

Use The corrugated sheet obtained by the method of the present invention can be laminated and bonded by being stacked or wound in multiple stages to form a multi-stage structure, and in actual use, it can be applied to such a multi-stage structure. It is thought that it will increase.

The above-mentioned call gate processed sheet and a multi-stage structure obtained by laminating and bonding the same in a multi-stage form include a total heat exchanger, a sensible heat exchanger, a humidifying element, a transpiration plate, a water absorption plate, a humidity control plate, a humectant, an air freshener, Odorant holding material, filters, heat insulating material, soundproofing material,
It can be used for various applications including vibration insulators, moisturizers, interior materials, and packaging materials.

Action FIG. 1 is an explanatory view of an essential part showing an example of the method of the present invention. (1) is an upper roll, (2) is a lower roll,
(3) is a press roll, (4) is a gluing roll, (5)
Is a finger. The finger (5) is preferably of a type (single-finger type) in which one half of the lower roll (2) is covered by one sheet from the upper roll (1) via the gluing roll (4).

The step-formed sheet (b), which is a difficult-to-form sheet, is supplied to the upper roll (1). At this time, an easily formable sheet (c) such as paper is applied from above the step-formed sheet (b). Gauze

The step-formed sheet (b) and the easily formable sheet (c) are step-processed by engagement of the upper roll (1) and the lower roll (2), and the lower roll (2) is pressed by the finger (5). Move to Due to this transition, the step-formed sheet (b) and the easily-formable sheet (c) are reversed, so that the easy-formable sheet (c) is placed on the lower side (lower roll (2)) of the lower roll (2). On the contact side), the step-formed sheet (b) is on the upper side. In this state, the adhesive is applied to the convex portion of the step-formed sheet (b) by the gluing roll (4).

Since the flat sheet (a) is sent from the press roll (3) along its surface, the flat sheet (a) is contacted with the press roll (3) pressed toward the lower roll (2). Then, the above-mentioned laminated sheet of the hard-formable sheet (b) / easy-formable sheet (c), which has been glued, is adhered.

Next, the easily formable sheet (c) is peeled off from the adhesive.

During the step processing by meshing the upper roll (1) and the lower roll (2), the step-formed sheet (b), which is a difficult-to-form sheet, is pressed by the easy-form sheet (c). The sheet is processed at the same time as the shaping sheet (c), and does not float from the lower roll (2) even when the upper roll (1) shifts to the lower roll (2). Moreover, since the easily formable sheet (c) is on the lower side in the lower roll (2), even when the density of the step-formed sheet (b) is small and the adhesive penetrates, the lower roll of the adhesive is used. Adhesion to (2) is effectively prevented.

EXAMPLES Next, the present invention will be further described with reference to examples.

Example 1 Using a corrugator for corrugated cardboard production shown in FIG.
A corrugated sheet was manufactured under the following conditions.

The corrugation was smooth, and a beautiful corrugated sheet was obtained as in the case of corrugated board production. No adhesion of the adhesive to the lower roll (2) was observed.

・ Step rolls (1), (2) For B-flute production, diameter: (1) 204 mm, (2) 207 mm ・ Flat sheet (a) Nonwoven fabric made of polyester fiber with a basis weight of 140 g / m ² and width of 1000 mm ・ Step forming sheet (B) Nonwoven fabric made of polyester fiber with a basis weight of 140 g / m ² and a width of 1000 mm ・ Easily shapeable sheet (c) Pure white roll paper with a basis weight of 35 g / m ² and a width of 1000 mm ・ Finger (5) Single finger, spacing 40 mm -Adhesive Adhesive mainly composed of raw starch and vinyl copolymer emulsion-Laminating speed 30 m / min Comparative Example 1 Example 1 except that the easily formable sheet (c) was not used.
Was repeated, but because the step workability of the step-formed sheet (b) was insufficient, the transition from the upper roll (1) to the lower roll (2) caused lifting from the lower roll (2), resulting in smooth corrugating. Could not. Adhesion of the adhesive to the lower roll (2) was observed.

When the laminating speed was extremely reduced or when the interval between the fingers (5) was extremely narrowed, the production of the corrugated sheet was not impossible, but the obtained corrugated sheet was partially removed. Floating was observed.

Example 2 Using a corrugator for corrugated cardboard production shown in FIG.
A corrugated sheet was manufactured under the following conditions.

Also in this case, the corrugated processing was smooth, and a beautiful corrugated sheet as in the case of corrugated board production could be obtained. No adhesion of the adhesive to the lower roll (2) was observed.

・ Step roll (1), (2) For A flute production, diameter: (1) 400mm, (2) 400mm ・ Flat sheet (a) Non-woven fabric made of polypropylene fiber with a basis weight of 200g / m ² and a width of 1200mm ・ Step forming sheet (B) Nonwoven fabric made of polypropylene fiber with a basis weight of 200 g / m ² and a width of 1200 mm ・ Easy-to-form sheet (c) Ryosara kraft paper with a basis weight of 75 g / m ² and a width of 1200 mm ・ Fingers (5) Single finger, spacing 75mm ・ Adhesive Adhesive based on water-resistant corn starch ・ Lamination speed 15m / min Effect of the present invention According to the present invention, even if a hard-to-form sheet (b) such as a nonwoven fabric is used, it can be used on an industrial scale. Can be corrugated. Further, even if the hardly formable sheet (b) into which the adhesive penetrates is used, troubles such as adhesion of the adhesive to the lower roll do not occur.

[Brief description of the drawings]

FIG. 1 is an explanatory view of an essential part showing an example of the method of the present invention. (1) ... upper roll, (2) ... lower roll, (3) ... press roll, (4) ... glue roll, (5) ... finger, (a) ... flat sheet, (b) ... step-formed sheet, (c) ... easily shapeable sheet

Claims (2)

(57) [Claims] In producing a corrugated sheet having a configuration in which a flat sheet (a) and a step-formed sheet (b) are laminated and bonded by a corrugator, at least one of the flat sheet (a) and the step-formed sheet (b) is used. A difficult-to-form sheet is used as the step forming sheet (b)
When supplying the step-formed sheet (b) to the upper roll of the single facer of the corrugator, the easy-to-form sheet (c) is applied from above the step-formed sheet (b), and the step-formed sheet (b) and the flat sheet ( A method for producing a corrugated sheet, wherein the easily formable sheet (c) is peeled off after lamination and adhesion with a). 2. The method according to claim 1, wherein the difficult-to-form sheet is a nonwoven fabric, and the easy-form sheet is paper.