JP3819405B2 - Composite sheet and manufacturing method thereof - Google Patents

Description

  The present invention is a bulky composite sheet composed of a base layer and a surface layer composed of a continuous fiber group, and in particular, absorbs disposable sheets, body fluids, etc. for wiping off dust such as floors, walls, windows, etc. It is related with the thing suitable for using as a disposable sheet | seat for this, a sheet | seat for cushioning materials, etc.

  8 and 9 are perspective views of a conventional example of a composite sheet 101 formed by joining continuous fibers to a base sheet such as a nonwoven fabric, and FIG. 10 is a perspective view of a holder 103 to which the composite sheet 101 is attached. Such a composite sheet 101 and the holder 103 are disclosed in Japanese Patent Laid-Open No. 9-149873. When the holder 103 is held in hand and the floor is rubbed, dust can be collected on the upper surface of the composite sheet 101 shown in FIGS. In the composite sheet 101, the base sheet 107 and a large number of continuous fibers 108 are integrated via the joining line 105. Such a composite sheet 101 can be manufactured by superposing the base sheet 107 and the continuous fiber 108 and supplying them between a pair of heated embossing rolls. However, when there are many intersections 131 between the joining lines 105 as in the joining line 105 in FIG. 8, in the manufacturing process of the composite sheet 101, there is a problem that unevenness in the distribution of the continuous fibers 108 is likely to occur near the intersections 131. is there.

  In the composite sheet 101 of FIG. 9, when the continuous fiber 108 and the base sheet 107 are supplied to the embossing roll in the direction of arrow P and the joining line 105 is sequentially formed in the direction of arrow Q, the continuous fiber 108 is in the direction of arrow Q. There is a problem that it is difficult to make the distribution of the continuous fibers 108 uniform in the width direction of the composite sheet 101.

  Accordingly, an object of the present invention is to provide a bulky composite sheet that can solve the above-described problems of the prior art and a method for producing the same.

  In order to solve the above problem, one of the objects of the present invention includes a base layer having a longitudinal axis, an upper surface and a lower surface, and a group of continuous fibers extending along the axis, A surface layer having a predetermined width defined between opposing side edges extending along an axis, and being joined to at least one of the upper and lower surfaces by a plurality of joining lines extending in a direction intersecting the axis; Is a composite sheet.

  In such a composite sheet, the features of the present invention are as follows.

It said joining lines, and a plurality of first bonding line formed in a straight line on one side region of the previous SL-axis of said surface layer, a plurality of second joining lines formed in a straight line on the side region of the other side Consists of
Wherein the first joining line and the second bonding lines and extend toward the axis intersects the surface of the continuous fiber groups and obliquely intersect each other, with other bonding line for any joint line the number of intersection lies in the fact Ru 0 or 1 der.

  In the composite sheet according to the present invention, continuous fibers are bonded to the base layer with a uniform thickness, and the fiber distribution is uniform. When this composite sheet is used as a cleaning sheet, it becomes easy to wipe the floor surface and the like uniformly.

  The composite sheet of the present invention can be used for general household cleaning and other various articles and is very useful for practical use.

  In order to solve the above-mentioned problem, another one of the objects of the present invention is as follows.

Superposing a surface layer web made on a base layer web from a continuous fiber groups, Ru method der for manufacturing a composite sheet by both web and fed between a pair of rotating embossing roll to form a plurality of bonding lines.

In the production method, and it is the present invention is characterized, extending the tow for the continuous fiber group of the surface layer web to open fiber to a step of expanding the required width, and the length of the pre-Symbol surface web a first joining line Oite straight on one side region of the axis, and a second joining line Oite straight to the side region of the other side, and a second joining line between the first joining line, When extending toward the axis, it intersects with the continuous fiber group of the surface web obliquely so as to intersect with each other, and the number of intersections with other joining lines is 0 or 1 for any joining line. The method includes a step of sequentially forming the surface layer from the axial direction toward the outer side in the width direction of the surface web.

  The details of the composite sheet and the manufacturing method thereof according to the present invention will be described with reference to the accompanying drawings.

  1 and 2 are a perspective view of a floor cleaning sheet 1 which is an example of a composite sheet, and a sectional view taken along line II-II. The cleaning sheet 1 has a plurality of joints in which a surface layer 8 made of a large number of thermoplastic continuous fibers 8a extends from a longitudinal axis CC (see FIG. 3) to both side edges 8c on the upper surface of a base layer 7 made of a thermoplastic nonwoven fabric. The sheet 1 is welded at the line 5, and the sheet 1 can wipe off the floor dust at the continuous fiber 8 a portion of the surface layer 8 by fixing the side edges 9 of the base layer 7 to the holder 103 of FIG. 10. . The sheet 1 can also be used by rubbing by hand. The continuous fibers 8a of the surface layer 8 spread between the side edges 9 and 9 of the base layer 7 and extend in parallel to each other in the length direction of the base layer 7 indicated by the arrow A. Since the continuous fiber 8a of the surface layer 8 is solidified after being melted at the joining line 5 by heating and pressing, it almost loses its fiber form, defines a compressed groove, and has an arc shape between the compressed grooves. A raised area 8b is defined. The height of the arcuate raised area is preferably at least three times the total thickness of the portion of the joining line 5 (the bottom of the compressed groove) and the base layer 7. Such a surface layer 8 exhibits not only a three-dimensional appearance but also excellent bulkiness, elasticity and compressibility, and it goes without saying that such properties are much higher than that of the base layer. When such a cleaning sheet 1 touches the floor with the continuous fiber 8a of the surface layer 8 and moves it in the direction of arrow A or in the direction of arrow B perpendicular to the arrow A, the continuous fiber 8a defining the arc rubs the floor, Garbage can be taken in between 8a and 8a. The continuous fiber 8a is welded to the both end portions in the arrow A direction of the base layer 7 with a joining line 15. However, the joining line 15 is not always necessary.

  FIG. 3 is a plan view of the cleaning sheet 1. The individual continuous fibers 8a of the surface layer 8 are schematically drawn widely. The width of the surface layer 8 is substantially bisected by the axis CC, and a plurality of first joining lines 5A among the joining lines 5 are formed above the figure on one side of the axis CC. A plurality of second joining lines 5B of the joining lines 5 are formed on the lower side of the figure on the other side. The plurality of first joining lines 5A are formed in parallel with each other at equal intervals, and the second joining lines 5B are also the same. The first and second joining lines 5A and 5B extend obliquely intersecting with the continuous fibers 8a of the surface layer 8, and are continuous with the surface layer 8 so that they can intersect each other when extending toward the axis CC. It is inclined with respect to the fiber 8a. However, in the illustrated example, the first and second joining lines 5A and 5B are already in an intersecting state on the axis CC. Further, the first and second joining lines 5A and 5B extend to the side edge 9 of the base layer 7 at the same angle with respect to the axis C-C, in other words, the continuous fiber 8a of the surface layer 8. ing. The first joint line 5A and the second joint line 5B have first ends 11A and 11B located on the axis CC and second ends 12A and 12B located near the side edge portion 9.

In FIG. 3, an imaginary line H extending in the width direction of the cleaning sheet 1 perpendicular to the axis CC is shown. The first and second joint lines 5A and 5B are other first lines in which a virtual line H drawn so as to intersect with the first ends 11A and 11B of the first and second joint lines 5A and 5B is parallel to the joint lines 5A and 5B. The second ends 12A and 12B of the two junction lines are also formed so as to intersect. Speaking in the illustrated example, virtual line H ₁ intersecting the first end 11A of the first joining line 5A is intersects the second end 12A of the next first joining line 5A skip immediately first joining line 5A next ing. All of the continuous fibers 8a of the surface layer 8 extending in the direction of arrow A in parallel with each other are bonded to the base layer 7 by the first bonding line 5A or the second bonding line 5B, and do not fall off the layer 7.

The size of the cleaning sheet 1 is not particularly limited, but preferably, the length of the base layer 7 is in the range of 5 to 200 cm and the width is in the range of 5 to 50 cm. The base layer 7 can be made of a material having dimensional stability such as a woven fabric, a nonwoven fabric, a thermoplastic synthetic resin film made of a thermoplastic synthetic fiber, and a preferable example of a nonwoven fabric is a composite fiber of polyethylene and polyester. Spunbond nonwoven fabric and point bond nonwoven fabric using It is preferable to use a nonwoven fabric or a film having a basis weight of 5 to 200 g / m ² .

For the continuous fibers 8a of the surface layer 8, continuous fibers such as polyethylene, polypropylene, nylon, polyester, rayon and the like can be used. As an example of a preferable continuous fiber 8a, there may be mentioned a fiber that has been expanded to a required width while a tow that is a bundle of continuous fibers 8a is opened by a known method. Tow is commercially available and is a rope-like bundle of continuous polymer filaments. A filament having a diameter of 1 to 20 d can be used. When the continuous fiber 8a of the surface layer 8 is crimped, it becomes bulky and flexible, so it is suitable for lightly wiping off floor dust, and reliably holds the wiped dust. It is excellent in that it can. The number of crimps of the crimped continuous fiber 8a is preferably 5 to 25 / 2.54 cm. The basis weight of the continuous fiber 8a of the surface layer 8 is preferably in the range of ^{20 to} 500 g / m2. The continuous fibers 8a can be treated with an oil agent or subjected to a hydrophilic treatment to improve floor wiping and moisture wiping performance.

  The joining line 5 is preferably a line in which the base layer 7 and the continuous fiber 8a of the surface layer 8 are welded, and is inclined in the range of 10 to 80 °, more preferably 15 to 75 ° with respect to the axis CC. Can be made. Although there is no special restriction | limiting in the width | variety of the joining line 5, Generally it is preferable to exist in the range of 0.5-10 mm.

  In the illustrated example, the continuous fibers 8 a of the surface layer 8 bonded only to the upper surface of the base layer 7 can be bonded to the lower surface of the base layer 7. When the continuous fibers 8a of the surface layer 8 are bonded to the upper and lower surfaces of the base layer 7, it is preferable to match the shape and position of the bonding line 5 on the upper and lower surfaces.

4 to 6 are drawings similar to FIG. 2 illustrating the embodiment of the present invention. In the cleaning sheet 1 in FIG. 4, the first joining line 5A, the first end 11A of the 5B, the first joining line 5A of the virtual line _{H 1} Gasugu next intersecting 11B, the second end 12A of 5B, intersects with 12B Yes.

The joining lines 5 of the cleaning sheet 1 in FIG. 5 are all relatively short, and the first joining line 5A above the axis CC has a first end 11A on the axis CC. First short joint line 5C and a relatively short first joint line 5D having a second end 12A at side edge 9 of base layer 7, and second joint line 5B below axis CC is A second joint line 5E having a first end 11B on the axis C-C and a second joint line 5F having a second end 12B at the side edge 9 of the base layer 7 are included. In the first and second joining lines 5A and 5B in FIG. 5, the first ends 11A and 11B are one ends near the axis CC of each joining line, and the second ends 12A and 12B are near the side edge 9. One end. 5C or imaginary line _{H 1} intersecting the first end 11A of the 5D of the first joining line 5A intersects the second end 12A of the immediately 5C or 5D of the first joining line 5A neighbors. The same applies to the relationship between the second bonding line 5B and the virtual line H. The continuous fiber 8a of the surface layer 8 is bonded to the base layer 7 by any of the first bonding line 5A including 5C and 5D and the second bonding line 5B including 5E and 5F, and may fall off from the layer 7. Absent.

The joining line 5 of the cleaning sheet 1 in FIG. 6 extends from the axis CC to the side edge 8c, but the first ends 11A and 11B of the first and second joining lines 5A and 5B have an axis C-. No cross on C. However, the first and second joining lines 5A and 5B are inclined with respect to the axis CC so as to intersect each other when extended in the direction of the axis CC. Virtual line _{H 1} intersecting the first end 11A of the first joining line. 5A intersects soon as the second end 12A of the first joining line 5A neighbors. The same applies to the relationship between the second bonding line 5B and the virtual line H.

  The cleaning sheet 1 having the joining line 5 illustrated in FIGS. 3 to 6 includes a web of the base layer 7 and a web of the surface layer 8 widened to a required width, and a pair of heated rotating embossing rolls. It can be manufactured by supplying continuously. At least one of the pair of embossing rolls is formed with an embossing protrusion corresponding to the bonding line 5, and each bonding line 5 extends from the axis CC to the base layer 7 with respect to the web of the surface layer 8. The embossing roll is rotated so as to be sequentially formed toward the side edge portion 9 of the web. In this way, even if the web of the surface layer 8 is supplied to the embossing roll in a state where the number of fibers is relatively large at the center portion in the width direction, the joining line 5 extends from the axis CC to the side edge portion 9. The web of the surface layer 8 spreads with a uniform thickness with respect to the web of the base layer 7 as it is formed.

FIG. 7 is a partially enlarged view of FIG. 3, and illustrates a state where the joint line 5 and the virtual line H intersect. The joining length L along the imaginary line H at an arbitrary position in the length direction (A direction) of the cleaning sheet 1 is the sum of the lengths of the portions where the joining line 5 and the imaginary line H intersect, for example, the junction length _{L 1} of the virtual line _{H 1 is} L 1 = a + b + c + d, junction length _{L 2} of the imaginary line _{H 2 is} L 2 = a + d + e . Depending on the shape of the joining line 5, the value of L may change depending on the position of the virtual line H in the cleaning sheet 1. In the manufacturing method of the cleaning sheet 1 according to the present invention, the value of L that changes The shape and position of the joining line 5 are adjusted so that the ratio of the maximum value to the minimum value is 2 or less. For example, as illustrated in FIGS. 3 to 6, when the virtual line H intersects with the first ends 11 </ b> A and 11 </ b> B of the joint line 5, it intersects with the second ends 12 </ b> A and 12 </ b> B of the other joint line 5 or other parts. To do. In this way, when the overlapped web of the base layer 7 and the web of the surface layer 8 are supplied to the embossing roll, the web of the base layer 7 and the web of the surface layer 8 are formed as protrusions for embossing formed on the roll. Thus, the embossing pressure acts on the web of the base layer 7 and the web and roll of the surface layer 8 throughout. That is, since the embossing pressure is not an intermittent form of acting or not acting, the continuous fiber 8a of the web of the surface layer 8 tends to spread on the base layer 7 with a uniform thickness, Embossing machines are less likely to be damaged.

  The laminated web of the web of the base layer 7 and the web of the surface layer 8 obtained by such a method is a composite sheet according to the present invention which is cut into an appropriate length after the joining line 15 of FIG. 3 is applied. The cleaning sheet 1 shown in the example is used. Such a composite sheet can be used as a cushioning material by increasing the bulk of the surface layer 8 as much as possible, or by using hydrophilic or water-absorbing fibers for the continuous fibers 8a of the surface layer 8, in addition to the use as the cleaning sheet 1. It can be used as a disposable or repetitive absorbent material for absorbing body fluids and other moisture.

The perspective view of the sheet | seat for cleaning. II-II sectional view taken on the line of FIG. The top view of the sheet | seat for cleaning. Drawing similar to FIG. 3 which shows another example of an embodiment. Drawing similar to FIG. 3 which shows another example of an embodiment. Drawing similar to FIG. 3 which shows another example of an embodiment. The elements on larger scale of FIG. The perspective view of the sheet | seat for cleaning of a prior art example. The perspective view of the sheet | seat for cleaning of a prior art example. The perspective view of the holder which attached the sheet | seat for cleaning.

Explanation of symbols

1 Composite sheet (cleaning sheet)
5, 5A, 5B, 5C, 5D, 5E, 5F Joining line 7 Base layer 8 Surface layer 8a Continuous fiber 8b Raised area 8c Side edge 9 Side edge CC axis H, H ₁ , H ₂ Virtual line

Claims (18)

A base layer having a longitudinal axis and having an upper surface and a lower surface, and a continuous fiber group extending along the axis, and having a predetermined width defined between opposing side edges extending along the axis And a composite sheet including a surface layer bonded to at least one of the upper and lower surfaces by a plurality of bonding lines extending in a direction intersecting the axis,
It said joining lines, and a plurality of first bonding line formed in a straight line on one side region of the previous SL-axis of said surface layer, a plurality of second joining lines formed in a straight line on the side region of the other side Consists of
Wherein the first joining line and the second bonding lines and extend toward the axis intersects the surface of the continuous fiber groups and obliquely intersect each other, with other bonding line for any joint line the composite sheet number of intersections and wherein 0 or 1 der Rukoto. With Oite the first joining line each other to one side region of said surface layer and extend parallel to one another at substantially regular intervals, the second joining lines with each other in a side region of the other is substantially regular The composite sheet according to claim 1, which extends in parallel with each other at a predetermined interval.   The composite sheet according to claim 1 or 2, wherein the continuous fiber group of the surface layer is obtained by opening a continuous fiber tow and expanding the continuous fiber toe into a substantially uniform web having a predetermined width.   The composite sheet according to claim 1, wherein each of the first and second joining lines defines a compressed groove.   The surface layer has a raised area that forms an arc between each pair of the first and second joining lines adjacent to each other, and each of the raised areas has higher bulkiness, elasticity, and compressibility than the base layer. 5. The height of the raised area is at least three times the total thickness of the first and second joining line portions and the base layer. The composite sheet described.   6. The composite according to claim 1, wherein the surface layer has a length extending in the axial direction of 5 to 200 cm, and the width extending in a direction intersecting the axial direction is in the range of 5 to 50 cm. Sheet. The basis weight of the base layer is in the range of 5 to 200 g / ^{m 2,} the composite sheet according to claim 1, the basis weight of the surface layer is in the range of 20 to 500 g / ^{m 2.}   The composite sheet according to any one of claims 1 to 7, wherein the continuous fiber group of the surface layer has a fineness per fiber of 1 to 20d. The composite sheet according to any one of claims 1 to 8, wherein the first and second joining lines intersect on a longitudinal axis that bisects the width of the surface layer . The composite sheet according to any one of claims 1 to 9, wherein the first and second joining lines extend from a longitudinal axis that bisects the width of the surface layer to an end of the surface layer. The maximum value with respect to the minimum value of the sum of the lengths of the portions intersecting the first and second joint lines of the imaginary line crossing the surface layer in the width direction perpendicular to the longitudinal axis that bisects the width of the surface layer The composite sheet according to any one of claims 1 to 10, wherein the ratio is 2 or less.   The composite sheet according to any one of claims 1 to 11, wherein the base layer and the surface layer contain a thermoplastic synthetic resin, and the first and second joining lines are formed by melting these synthetic resins. .   The composite sheet according to any one of claims 1 to 12, wherein the first and second joining lines are welding lines formed by pressure and heating. A method for producing a composite sheet by superimposing a surface layer web composed of a continuous fiber group on a base layer web and supplying both webs between a pair of rotating embossing rolls to form a plurality of joining lines ,
The step of expanding the required width tow as for continuous fiber group of the surface layer web to the open fiber, and
Before Symbol a first joining line Oite straight on one side region of an axis extending in the length direction of the surface layer web and a second joining line Oite straight to the side region of the other side, said first junction and the said the line second joining line and extending toward the axis so as to intersect with the obliquely superficial web of continuous fiber groups so as to intersect each other, and yet, the intersection of the other bonding wire for any joint line The method according to claim 1, further comprising a step of sequentially forming from the axis side toward the outer side in the width direction of the surface layer web so that the number of the first layer becomes 0 or 1 .   The manufacturing method according to claim 14, wherein the first and second joining lines extend in parallel with each other at substantially regular intervals in each of one side region and the other side region of the surface web.   Each of the first and second joining lines has a first end located closer to the axis and a second end located closer to the outer side of the surface layer web. An imaginary line crossing the surface web in the width direction across the first end of the joint line intersects a second end of another joint line parallel to the first or second joint line. The manufacturing method according to claim 14 or 15.   The first value is set so that a ratio of a maximum value to a minimum value of a sum of lengths in the width direction of a portion where an imaginary line crossing the surface layer web in the width direction intersects the first and second joining lines is 2 or less. The manufacturing method in any one of Claims 14-16 which forms a joining line and a 2nd joining line.   The manufacturing method according to claim 14, wherein the first and second joining lines are formed by melting the base layer web and the surface layer web.

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