JP5157953B2 - Non-woven fabric manufacturing method and manufacturing apparatus thereof - Google Patents

Description

  The present invention relates to a method for manufacturing a nonwoven fabric by a melt blow method and a manufacturing apparatus therefor.

  Conventionally, as a filter capable of collecting very small dust or the like, or as a moisture absorbent material having a good touch, nonwoven fabrics by melt blown method including ultrafine fibers have been used in various fields. This non-woven fabric is formed by laminating fibers that are further thinned by jetting high-temperature air onto long fibers made of synthetic resin spun into an endless shape.

  In the “method for producing an elastic stretchable composite sheet” disclosed in Patent Document 1, an elastic stretchable composite sheet that is used for a disposable diaper or the like has a suitable elastic stretchability. Yes. In this manufacturing method, a nonwoven fabric composed of two layers of fibers spun by a melt-blowing method is joined through embossing rollers. In addition, it is possible to join two layers by needle punching instead of the embossing roller.

  In the “nonwoven fabric manufacturing method and nonwoven fabric” disclosed in Patent Document 2, a plurality of protrusions are provided so that fibers in a semi-molten state are entangled, and the fibers are stacked in a standing state around the protrusions. At the same time, the spun fibers are formed in a suspension bridge shape between the protrusions so that many voids are formed between the fibers.

JP 2001-20171 A (see paragraphs [0015] [0016] [0023] of the specification) JP 2002-266222 A (see [Summary])

  In the apparatus used in the manufacturing method of Patent Document 1, the first web is discharged from the first molding machine onto the belt running in the direction from the first melt blown fiber molding machine to the second melt blown fiber molding machine. A second web is discharged from the second molding machine thereon. However, since the semi-molten fibers discharged from the first molding machine are supplied directly onto the belt, some of the fibers are scattered without being laminated at predetermined positions on the belt depending on the discharge conditions and the like. There is a fear. At this time, since the discharged fiber is extremely fine, it is easily affected by hot air used for discharging, and it cannot be said that it is easy to adjust the discharging conditions to prevent the fiber from scattering.

  In addition, in the manufacturing method of Patent Document 2 which is an invention by the present applicant, the fiber is entangled with a plurality of protrusions protruding on the molding surface, and the molding surface formed by a metal mesh or the like to which the fiber is supplied is reflected. Since no wind is generated, unlike the case where the fiber is supplied directly onto the belt, there is almost no possibility of the fiber scattering. However, the non-woven fabric produced by this manufacturing method is entangled with the protrusions or suspended in a suspension bridge shape between the protrusions. Is accompanied by the annoyance that must be done carefully. In addition, since the density of the fibers entangled with the protrusions or suspended in a suspension bridge shape between the protrusions is not uniform, the nonwoven fabric manufactured by this manufacturing method is limited to a specific application. I must.

  The present invention has been made paying attention to such a problem, and the object of the present invention is that the fiber spun in a semi-molten state is supplied onto the molding machine without being scattered and uniformly. It is providing the manufacturing method which forms the laminated nonwoven fabric.

In order to solve the above problem, the invention of the nonwoven fabric manufacturing method according to claim 1 is characterized in that, in the nonwoven fabric manufacturing method by the melt-blowing method, a plurality of sharpened blades are fed to a molding machine to which spun semi-molten fibers are supplied. By providing a needle-like body and laminating the fibers between the needle-like bodies, the fibers are prevented from scattering, so that the needle-like body can be projected and retracted in an insertion hole provided in the molding machine. The needle-like body protrudes from the insertion hole onto the molding plate before the fiber is supplied, and the fiber protrudes from the insertion hole in the state where the needle-like body protrudes from the insertion hole. Laminated on a forming board, the needle-shaped body is inserted into the insertion hole of the molding machine after the laminated fibers are solidified to become a non-woven fabric, and the non-woven fabric from which the needle-shaped body is pulled out is inserted into the non-woven fabric. der those characterized by removing from the molding machine .

According to the first aspect of the present invention, since the plurality of sharp needle-like bodies are provided on the molding machine to which the spun, semi-molten fiber is supplied, the semi-molten fiber of the needle-like body is provided. It can supply between the needle-like bodies, without being entangled in the front-end | tip part. Therefore, it is possible to prevent the fibers from scattering. Alternatively, the semi-molten fibers can be laminated between the needles without suspending the fibers in the form of a suspension bridge to form a nonwoven fabric composed of a fiber layer in which the fibers are uniformly distributed. it can.
Furthermore, after the fibers in a semi-molten state are laminated between a plurality of needles protruding on the molding machine, and the fibers solidify into a nonwoven fabric, the needles are immersed in the insertion holes of the molding machine. And can be pulled out from the nonwoven fabric. For this reason, the nonwoven fabric can be easily removed from the molding machine from which the needle-like body has been removed.

The invention described in claim 2 is the method for producing a nonwoven fabric according to claim 1, wherein the semi-molten state fibers, as sequentially spun from a plurality of spinning heads for laminating a plurality of fiber layers The fibers that initially form the fiber layer are supplied from above the molding disk and needle-like body, are laminated between the needle-like bodies, and are spun from the next spinning head. Is supplied onto the needle-like body protruding from the already laminated fiber layer, and the spinning and lamination are repeated so as to be laminated between the needle-like bodies. A non-woven fabric made of a fiber layer is formed.

According to the second aspect of the present invention, when forming a nonwoven fabric composed of a plurality of fiber layers, since a plurality of needle-like bodies protrude from the already formed fiber layer, the next spinning is performed from the spinning head. Further, it is possible to prevent the fibers in a semi-molten state from being supplied between the needle-like bodies to be scattered and to form the next fiber layer between the needle-like bodies.

According to a third aspect of the present invention, in the method for producing a nonwoven fabric according to the second aspect , the needle-like body is formed with a burr at the tip, and the needle-like body is sequentially pulled out from the uppermost fiber layer. While being inserted into the insertion hole of the molding machine, the needle-like burrs entangle the fibers of each of the laminated fiber layers.

According to the invention described in claim 3 , when forming a nonwoven fabric composed of a plurality of fiber layers, the needle-shaped burrs are formed by pulling out the needle-like body whose tip is located in the uppermost fiber layer, so that the fibers of each layer By hooking, the fibers of the upper and lower fiber layers can be entangled with each other. Therefore, since the entanglement force between the fibers is added to the welding force between the fiber layers, more reliable bonding between the fiber layers can be performed. In addition, the “burr” used here refers to a protruding portion capable of hooking a fiber.

The invention according to claim 4 is the nonwoven fabric manufacturing apparatus used in the nonwoven fabric manufacturing method according to any one of claims 1 to 3 , wherein there are a plurality of spinning outlets for spinning the semi-molten fiber. A spinning machine formed, a molding machine movable horizontally in the lower part of the spinning head so that the fibers spun from the spinning head are stacked, and the molding machine is provided And a sharp needle-like body supported by the support so as to be able to appear and retract in the plurality of insertion holes.

According to the invention described in claim 4 , since the plurality of sharp needle-like bodies are provided on the molding machine to which the spun semi-melted fibers are supplied, the semi-melted fibers are converted into the needle-like bodies. It can be supplied between the needle-like bodies without being entangled with the tip portion of the, and can be prevented from scattering. Further, after the fibers in a semi-molten state are laminated and solidified between a plurality of needle-like bodies protruding on the molding machine, the needle-like bodies can be immersed in the insertion holes of the molding machine. Therefore, the nonwoven fabric formed by solidifying the fiber layer can be easily removed from the molding machine from which the needle-like body has been removed.

According to a fifth aspect of the present invention, in the nonwoven fabric manufacturing apparatus according to the fourth aspect , a plurality of the spinning heads are provided, and the fibers spun from each spinning head are supplied to the plurality of fiber layers. The forming disk is horizontally movable under the respective spinning heads, and the needle-like body is formed with burrs, the burrs being the uppermost of the plurality of fiber layers. It arrange | positions so that it may be located in a fiber layer, It is characterized by the above-mentioned.

According to the fifth aspect of the present invention, since the semi-molten fibers can be spun sequentially from the plurality of spinning heads, a nonwoven fabric composed of a plurality of layers can be formed. Further, when pulling out the needle-like body from the plurality of fiber layers, the burrs located in the uppermost fiber layer can hook the fibers of each layer and entangle the fibers of the upper and lower fiber layers. Therefore, the fiber layers can be bonded by the intertwined fibers.

The invention according to claim 6 is the nonwoven fabric manufacturing apparatus according to claim 4 or 5 , wherein the support is provided so as to be movable in a direction perpendicular to the arrangement direction of the spinning outlets below the spinning head. The molding disk is placed on the support, and the molding disk is placed on the support and the position where the needle-like body above the placement position is inserted into the insertion hole. It is supported by the said support body so that a vertical movement is possible.

According to the sixth aspect of the present invention, the molding disk placed on the support body can be moved upward together with the nonwoven fabric made of the cooled and solidified fiber, so that the needle-like body supported by the support body Can be moved relatively downward and pulled out from the nonwoven fabric to be removed from the molding machine. Therefore, the nonwoven fabric can be easily removed from the molding board.

  According to the present invention, since the fiber spun in a semi-molten state is supplied between a plurality of sharp needles provided on the molding machine, it is possible that the fiber will scatter. The manufacturing method and manufacturing apparatus which form a nonwoven fabric with the fiber which was prevented and was laminated | stacked uniformly between the acicular bodies can be provided.

The perspective view which shows typically the manufacturing apparatus used for the manufacturing method of 1st Embodiment of this invention. The partial cross section figure which expands and shows the A section in FIG. The schematic diagram which shows the fiber supplied between acicular bodies. The partial cross section figure which shows the state where the acicular body was pulled out from the nonwoven fabric. The partial cross section figure which shows typically the manufacturing method of 2nd Embodiment of this invention. The partial cross section figure which shows typically the manufacturing method of 3rd Embodiment of this invention. The side view which shows typically the manufacturing apparatus used for the manufacturing method of 4th Embodiment of this invention.

(First embodiment)
DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments embodying the present invention will be described with reference to FIGS.
As shown in FIG. 1, a manufacturing apparatus 1 used in the manufacturing method of the present embodiment has a forming disk 4 and a support 5 arranged below a spinning head 2 connected to a synthetic resin extrusion apparatus (not shown). Yes. As a part of the conveyor, the support 5 is installed so as to be movable in the horizontal direction from the right to the left in the figure. The molding board 4 is a stainless steel plate-like body having a plurality of insertion holes 4a, and is supported on the support body 5 so as to be movable up and down. In FIG. 1, five rows of a plurality of needle-like bodies 3 are drawn. However, the needle-like bodies 3 are arranged at predetermined intervals over the entire molding plate 4, and some of the illustrations are shown. Is omitted.

As shown in FIG. 2, the sharp needle-shaped body 3 made of stainless steel is supported by the support body 5 and is inserted through the insertion hole 4 a of the molding board 4 so as to protrude from the upper surface of the molding board 4. Yes.
As shown in FIGS. 1 and 3, on the molding machine 4 that has moved below the spinning head 2 as the support 5 travels, and the needle-like body 3 that projects on the molding machine 4. In contrast, the fibers 6 are continuously supplied from above. At this time, since the fiber 6 spun from the spinning head 2 is urged downward by the hot air, it is in a state of being easily scattered upon hitting an obstacle. However, as shown in FIG. Since it is supplied between the bodies 3, the scattering of the fibers 6 is prevented in advance. In FIG. 3, the fibers 6 are drawn as if they were supplied and laminated, but the fibers 6 spun from the spinning head 2 are very fine long fibers.

  Thus, since the fiber 6 spun from the spinning head 2 does not scatter, the side plate which prevents the fiber 6 from scattering to the left and right ends of the molding machine 4 at the left and right ends of the molding machine 4. There is no need to provide. Therefore, the nonwoven fabric on which the fibers 6 are laminated has a uniform density without any difference in density between the center portion of the molding machine 4 and the left and right end portions.

  The fibers 6 uniformly laminated between the needle-like bodies 3 are solidified into a nonwoven fabric 10 after a predetermined cooling time. And the nonwoven fabric 10 and the molding disk 4 which moved to the downstream side of the spinning head 2 move above the support body 5 by a vertical movement drive device (not shown) as shown in FIG. Then, the needle-like body 3 protruding from the insertion hole 4 a of the molding board 4 is immersed in the insertion hole 4 a and is pulled out from the nonwoven fabric 10 on the molding board 4. At this time, since the needle-like body 3 is pulled out without being inclined from the state embedded in the nonwoven fabric 10, the trace 3a of the needle-like body 3 is reduced in size so that it is difficult to visually recognize. Then, the nonwoven fabric 10 can be easily removed from the forming board 4.

Therefore, according to the manufacturing method of the above embodiment and the manufacturing apparatus therefor, the following effects can be obtained.
(1) In the above embodiment, since the plurality of sharp needle-like bodies 3 are provided on the molding machine 4 to which the spun semi-molten fibers 6 are supplied, the semi-molten fibers 6 are shaped like needles. Without being entangled with the tip of the body 3, it can be supplied between the needle-like bodies 3. Therefore, scattering of the fiber 6 can be prevented in advance. Moreover, the nonwoven fabric 10 which consists of a fiber layer in which the fiber 6 of the semi-molten state was laminated | stacked between the acicular bodies 3 without laying between the acicular bodies 3 in the shape of a suspension bridge, and the fiber was distributed uniformly. Can be formed.

  (2) In the above embodiment, after the semi-molten fibers 6 are laminated and solidified between the plurality of needle-like bodies 3 protruding from the molding board 4, the needle-like bodies 3 are inserted into the insertion holes 4a of the molding board 4. I was able to immerse myself in. Therefore, the nonwoven fabric 10 formed by solidifying the fiber layer can be easily removed from the molding disk 4 from which the needle-like body 3 is removed.

  (3) In the above embodiment, the molding machine 4 is supported by the support 5 so that it can move up and down. Therefore, the needle-shaped body 3 supported by the support body 5 can be moved relatively downward and pulled out from the nonwoven fabric 10 on the molding board 4. Therefore, the nonwoven fabric manufacturing apparatus which can remove the nonwoven fabric 10 from the molding board 4 easily can be provided.

(Second Embodiment)
Next, a second embodiment that embodies the present invention will be described with reference to FIG. 5 with a focus on differences from the first embodiment.

  In the present embodiment, although not shown, the manufacturing apparatus 1 shown in FIG. 1 is an apparatus in which two spinning heads 2 are arranged along the traveling direction of the support 5. Then, the semi-molten fibers 6 are sequentially supplied from the two spinning heads 2 on the molding machine 4 and between the plurality of needle-like bodies 30, and as shown in FIG. A nonwoven fabric 20 composed of two fiber layers 12 is formed.

  As is clear from FIG. 5, the needle-like body 30 is formed with a spine-shaped burr 31. The burrs 31 of the needle-like body 30 are arranged so as to be positioned at least above the boundary between the first fiber layer 11 and the second fiber layer 12. Accordingly, after the first fiber layer 11 is formed by the fibers 6, the needles 30 protrude upward from the first fiber layer 11, so that the fibers 6 for forming the second fiber layer 12 are supplied. At that time, the needles 30 prevent the fibers 6 from being scattered.

  Further, when pulling out the needle-shaped body 30 from the nonwoven fabric 20, the burrs 31 hook the fibers 6 of the second fiber layer 12, so that the fibers 6 of the second fiber layer 12 and the fibers 6 of the first fiber layer 11 below the fibers 6 Can be entangled. Accordingly, the first fiber layer 11 and the second fiber layer 12 are firmly bonded.

  Further, when the density relationship between the first fiber layer 11 and the second fiber layer 12 is made dense, the fibers 6 forming the second fiber layer 12 that becomes a dense layer are spun from the spinning head 2. Later, the time from the semi-molten state to solidification is short. Therefore, even if there is time for welding the fibers 6 to form the second fiber layer 12, the time for bonding the first fiber layer 11 and the second fiber layer 12 formed earlier is sufficient. However, it is hard to say that the welding power as a semi-molten state remains. Therefore, the bonding force between the first fiber layer 11 and the second fiber layer 12 by the burr 31 of the needle-like body 30 acts effectively.

And in this 2nd Embodiment, in addition to the effect in 1st Embodiment, the following effects can be acquired.
(4) In the above embodiment, when forming the nonwoven fabric 20 composed of the first fiber layer 11 and the second fiber layer 12, a plurality of needle-like bodies 30 protrude on the already formed first fiber layer 11. Then, the semi-molten fiber 6 spun from the spinning head 2 was supplied between the needles 30. Therefore, scattering of the fibers 6 can be prevented, and the nonwoven fabric 20 can be formed by laminating the first fiber layer 11 and the second fiber layer 12 between the needle-like bodies 30.

  (5) In the above embodiment, by pulling out the needle-like body 30 whose tip is located in the second fiber layer 12, the burrs 31 of the needle-like body 30 hook the fibers 6 of the second fiber layer 12, and the second fibers The fibers 6 of the layer 12 and the first fiber layer 11 are entangled with each other. Therefore, more reliable bonding between the first fiber layer 11 and the second fiber layer 12 can be performed.

(Third embodiment)
Next, a third embodiment embodying the present invention will be described with reference to FIG. 6 with a focus on differences from the first and second embodiments.

  As shown in FIG. 6, in this embodiment, a three-layer nonwoven fabric 21 composed of a first fiber layer 11, a second fiber layer 12, and a third fiber layer 13 is formed. For this reason, the spinning head 2 is provided at three locations.

  In addition, the density relationship between the first fiber layer 11, the second fiber layer 12, and the third fiber layer 13 is rough, medium density, and dense, and the binding force of the second fiber layer 12 with respect to the first fiber layer 11. Alternatively, the binding force of the third fiber layer 13 to the second fiber layer 12 is obtained by the action of the burrs 31 of the needle-like body 30 entangle the fibers 6 of each layer.

And in this 3rd Embodiment, in addition to the effect in 1st and 2nd Embodiment, the following effects can be acquired.
(6) In the above embodiment, the nonwoven fabric 21 composed of the first fiber layer 11, the second fiber layer 12, and the third fiber layer 13 is formed, and the needle-like body is formed on the uppermost third fiber layer 13. 30 burrs 31 were located. Therefore, when the burrs 31 entangle the fibers 6 of each layer, the first fiber layer 11, the second fiber layer 12, and the third fiber layer 13 are composed of three layers that are more reliably bonded to each other. The nonwoven fabric 21 can be provided.

(Fourth embodiment)
Next, a fourth embodiment embodying the present invention will be described with reference to FIG. 7 with a focus on differences from the first to third embodiments.

  As shown in FIG. 7, the forming board 40 in the manufacturing apparatus 41 of the present embodiment is formed in a wave shape. By doing in this way, for example, the nonwoven fabric 20 composed of two layers of coarse and dense is formed into a wave shape, and the nonwoven fabric 20 is suitably used for an air filter or the like for efficiently collecting dusts having different sizes. Can do.

  In addition, in the manufacturing apparatus 41 of the present embodiment, the needle-like body 30 having the burrs 31 is provided. However, when the one-layer nonwoven fabric 10 is formed, the needle-like bodies 3 without the burrs 31 are used. It ’s enough.

And in this 4th Embodiment, in addition to the effect in 1st-3rd embodiment, the following effects can be acquired.
(7) In the above embodiment, the forming disk 40 formed in a wave shape is used. For this reason, since the nonwoven fabrics 10, 20, and 21 can be formed in a wave shape, the nonwoven fabric used suitably for a filter etc. can be provided.

(Example of change)
In addition, the said embodiment can also be changed and actualized as follows.
The molding disk 4 is supported by the support 5 so as to be movable upward, but the molding disk 4 is moved horizontally so that the needle-shaped body 3 can be pulled out from the molding disk 4 to support the molding body. Move 5 down.
The needle-like bodies 3 and 30 and the molding machines 4 and 40 are made of stainless steel, but are made of steel or non-ferrous metal. At that time, you may make it perform the process for providing well-known mold release property.
-Although the molding machines 4 and 40 are plate-shaped bodies, the molding machines 4 and 40 and the support 5 are formed of a net-like body or a punching board, and if necessary, a suction air flow is generated downward by a blower.

  DESCRIPTION OF SYMBOLS 1,41 ... Manufacturing apparatus, 2 ... Spinning head, 3,30 ... Needle-like body, 4,40 ... Molding board, 4a ... Insertion hole, 5 ... Support body, 6 ... Fiber, 10, 20, 21 ... Nonwoven fabric, 31 ... Kaeri.

Claims (6)

In the manufacturing method of the nonwoven fabric by the melt blow method,
By providing a plurality of sharp needle-like bodies on a molding machine to which spun semi-molten fibers are supplied, and by laminating the fibers between the needle-like bodies, preventing the scattering of the fibers ,
The needle-like body is supported by a support so as to be able to appear and retract in an insertion hole provided in the molding machine,
The needle-like body protrudes from the insertion hole onto the molding board before the fiber is supplied,
The fiber is laminated on the molding board in a state where the needle-like body protrudes from the insertion hole,
The needle-shaped body is immersed in the insertion hole of the molding machine after the laminated fibers are solidified to form a nonwoven fabric, and the nonwoven fabric from which the needle-shaped body has been pulled out is removed from the molding machine. A method for producing a nonwoven fabric. The fibers in the semi-molten state are sequentially spun from a plurality of spinning heads for laminating a plurality of fiber layers, and the fibers that form the fiber layers first include the molding machine and the needle-shaped body. And the fibers spun from the next spinning head are fed onto the needles protruding from the already laminated fiber layers. The nonwoven fabric according to claim 1, wherein a nonwoven fabric composed of a plurality of fiber layers is formed by repeating the spinning and lamination so as to be laminated between the needle-like bodies. Production method. The needle-like body is formed with burrs at the tip, and the needle-like burrs are stacked while the needle-like bodies are sequentially pulled out from the uppermost fiber layer and immersed in the insertion hole of the molding machine. The method for producing a nonwoven fabric according to claim 2 , wherein the fibers of each fiber layer are entangled with each other. In the nonwoven fabric manufacturing apparatus used for the nonwoven fabric manufacturing method according to any one of claims 1 to 3 , a spinning head in which a plurality of spinning outlets for spinning semi-molten fibers are formed, and A molding machine that is movable in the horizontal direction below the spinning head so that the fibers spun from the spinning head are laminated, and can be projected and retracted in a plurality of insertion holes provided in the molding machine. A non-woven fabric manufacturing apparatus comprising a sharp needle-like body supported by a support body. A plurality of the spinning heads are provided, and the molding machine is horizontally disposed below each spinning head so that the fibers spun from each spinning head are supplied to form a plurality of fiber layers. 5. The device according to claim 4 , wherein the needle-shaped body is made movable, and the needle-like body is formed with a burr, and the burr is arranged in an uppermost fiber layer of the plurality of fiber layers. Non-woven fabric manufacturing equipment. The support is provided below the spinning head so as to be movable in a direction perpendicular to the direction in which the spinning outlet is disposed, and the molding disk is placed on the support, and the molding disk is The support body is supported by the support body so as to be vertically movable between a placement position on the support body and a position where the needle-like body above the placement position is immersed in the insertion hole. Item 6. The nonwoven fabric production apparatus according to Item 4 or 5 .

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