JP5546004B2 - Brush manufacturing method and brush - Google Patents

Description

The present invention relates to a brush manufacturing method capable of significantly increasing the fiber density of the brush fibers and improving the production efficiency in manufacturing the brush, and a brush obtained by using the brush manufacturing method.

Brushes composed of brush bases and brush fibers are used in various fields, and in particular, are suitably used as brushes for performing various processes such as cleaning, cleaning, charging, coating, grinding, and polishing. For example, in a manufacturing process, a cleaning brush used for cleaning or removing foreign matter has a problem that the quality of a product obtained is deteriorated due to the presence of foreign matter if the cleaning is insufficient.

On the other hand, as an example using a commonly used charging brush, as shown in Patent Document 1 and Patent Document 2, a conductive fiber composed of a conductive fiber excellent in charging performance and static elimination performance and a brush base is used. An articulated brush is disclosed that is formed by spirally winding and joining a support shaft made of a metal round bar.

However, with the recent technological innovation, the conventional conductive brush has insufficient removal capability. In addition, conventional conductive brushes have a problem in that the conductive fibers (brush fibers) sag as they are used, and it is difficult to maintain charging performance and cleaning performance over a long period of time.
Further, in the conventional conductive brush, the brush base is easily peeled off from the support shaft, and not only can the role of the conductive brush not be fulfilled sufficiently, but also the device itself may be destroyed.

Also, conventional conductive brushes are manufactured by applying an adhesive to one end of the brush fiber and fixing it to the brush base, or by brushing the brush fiber by pile weaving and weaving it into the brush base. ing.
However, the method of fixing with an adhesive has a problem that the fiber density of the brush fibers cannot be increased and a problem that the brush fibers are easily pulled out.
Further, the method of raising by pile weaving has a problem that not only the fiber density of the brush fibers is lowered, but also the weaving process becomes complicated and the working efficiency is lowered.

JP 2000-56538 A JP 2004-93948 A

In view of the above-mentioned present situation, the present invention can greatly increase the fiber density of the brush fibers, and can improve the production efficiency when manufacturing the brush, and the manufacture of the brush The object is to provide a brush obtained using the method.

The present invention includes a step of warping a brush fiber yarn, a step of attaching a brush substrate tape in a direction perpendicular to the warped brush fiber yarn, and heating the brush substrate tape to the brush fiber yarn. A step of fusing the strips for the brush fibers, a step of alternately folding the yarns for brush fibers, laminating the tapes for brush substrates by pressing in a horizontal direction while heating the tapes for brush substrates, and the tapes for brush substrates And a step of cutting the center in the thickness direction of the brush base tape in a horizontal direction, wherein the brush base tape is made of an elastic elastic elastomer resin having a tensile elongation of 100 to 900%. And a method for manufacturing a brush made of a material having a melting temperature 1/2 lower than that of the yarn for brush fibers.
The present invention is described in detail below.

Conventionally, as a method for manufacturing a brush, a method in which an adhesive is applied to one end of a brush fiber and the brush fiber is fixed to the brush base, or a method in which the brush fiber is raised by a pile weave and woven into the brush base is used. However, there has been a problem that the fiber density of the brush fibers cannot be increased and a problem that work efficiency is lowered.
In the method for manufacturing a brush of the present invention, by using the above-described method, the fiber density of the brush fiber can be significantly increased, and the production efficiency when manufacturing the brush can be improved. Moreover, the brush obtained is one in which the brush fibers are not easily detached.

An example of the manufacturing method of the brush of this invention is demonstrated using FIGS.
1 and FIG. 2A are schematic views from above, and FIG. 2B to FIG. 5 are cross-sectional views from the lateral direction.
In the present invention, first, the yarn 11 for brush fibers is warped at an appropriate interval (FIG. 1).
Next, the brush base tape 12 is attached at an appropriate interval in the vertical direction of the warped yarn 11 for brush fibers (FIG. 2A). Further, the brush base tape 12 is heated and fused to the brush fiber yarn 11 (FIG. 2B).
Then, the brush fiber yarns 11 are alternately folded, the brush base tape 12 is heated and pressed in the horizontal direction to laminate the brush base tape 12, and the brush base tapes are fused together ( FIG. 3). Next, a step of cutting the brush fiber yarn 11 into an appropriate length is performed. (FIG. 4).
Finally, the center of the brush base tape in the thickness direction is cut in the horizontal direction (FIG. 5). Thereby, the brush which has the brush base 2 and the brush fiber 1 is produced.

In the method for producing a brush of the present invention, first, a step of warping the yarn for brush fibers is performed.
Since the warp density of the yarn for brush fibers is determined according to the fiber density of the obtained brush, it is not particularly limited, but 15 to 200 yarns / cm can be exemplified.

Cotton yarn, polyester fiber, polyamide fiber, conductive fiber, etc. can be used as the yarn for the brush fiber.
The yarn for brush fibers may be a filament. Monofilament or multifilament can be used as the filament, but it is preferable to use multifilament.

Examples of the polyester fiber include polyethylene terephthalate, polybutylene terephthalate, polypropylene terephthalate, a copolymer obtained by copolymerizing a dicarboxylic acid component, a diol component or an oxycarboxylic acid component, or a polyester blended with these polyesters. Is mentioned. Furthermore, aliphatic polyesters such as polylactic acid, polybutylene succinate and polyε-caprolactam known as biodegradable polyesters may be used.

Examples of the polyamide fiber include nylon 6, nylon 66, nylon 69, nylon 46, nylon 610, nylon 12, polymetaxylene adipamide, and fibers made by copolymerizing or blending these components. Can be mentioned.

Examples of the conductive fibers include carbon fibers, composite fibers obtained by kneading carbon black into synthetic fibers such as nylon, acrylic and polyester, and synthetic fibers whose surface is coated with carbon black.
Specific examples of the conductive fibers include conductive rayon fibers REC-B, REC-C, REC-M1, REC-M10 (manufactured by Unitika Ltd.), SA-7 (manufactured by Toray Industries, Inc.), Thunderon (Nippon Eyelashes) There are commercially available products such as Berton (manufactured by KB Seiren), Kurabobo (manufactured by Kuraray), Roval (manufactured by Mitsubishi Rayon).

Although the thickness of the said yarn for brush fibers is not specifically limited, It is preferable that a fiber diameter is 5-300 micrometers. When the fiber diameter of the yarn for brush fibers is less than 5 μm, the fiber becomes weak, the brushing effect utilizing the rebound resilience of the fiber is difficult to obtain, and the fiber sag by continuous use tends to be fast. .
If the fiber diameter of the yarn for brush fibers exceeds 300 μm, uniform contact with the object to be brushed tends to be difficult to obtain, which is not preferable. By setting the thickness of the yarn for brush fibers within the above range, the brush has excellent uniform contact by brushing.

In the method for manufacturing a brush of the present invention, a step of applying a brush base tape in the vertical direction of the warped yarn for the yarn is then performed.
Since the space | interval at the time of sticking the said tape for brush bases is determined according to the length of the brush fiber obtained, it is although it does not specifically limit, It is preferable to be every 4 to 70 mm. By setting the interval at the time of applying the brush base tape within the above range, the brush has excellent uniform contact by brushing.

Examples of the brush base tape include a tape obtained by applying an adhesive to a base material made of an elastic elastic elastomer resin.
The brush base tape preferably has a thickness of about 5 to 50 μm and a width of about 1 to 10 mm.

The stretch elastic elastomer resin (hereinafter also simply referred to as an elastomer resin) returns to its original length even when stretched (has no yield point within the stretchable range), that is, rubber elasticity (10% in the hysteresis curve). There is no particular limitation as long as it is a thermoplastic elastomer. Examples of the elastomer resin include polyurethane and polystyrene butadiene block copolymers, and polyurethane elastomer is particularly preferable.

The elastomer resin has a tensile elongation of 100 to 900%. By setting the tensile elongation within the above range, the tensile elongation can be reliably fixed to the support shaft. The tensile elongation is preferably 100 to 600%.
The tensile elongation can be measured by a method based on JIS K 7311.

The tensile strength (JIS K 7311) of the elastomer resin is preferably about 30 to 60 MPa, more preferably about 45 to 60 MPa. The surface hardness A (JIS K 6253) is preferably about A70 to 98, and more preferably A80 to 90. When the surface hardness A is less than A70, it is difficult to ensure the strength, and when it exceeds A98, the elongation and stretchability tend to be extremely deteriorated.

Specific examples of the elastomer resin include, for example, Kuramilon U (manufactured by Kuraray Co., Ltd.) 3195, 8175, which is a thermoplastic polyurethane elastomer, Pandex (manufactured by DIC Bayer Polymer Co., Ltd.) T-1185N, 1190N, 1195N and the like. .

As an example of the method for producing the elastomer resin, a method for producing a polyurethane elastomer resin is shown below. The polyurethane elastomer resin can be produced, for example, from an aromatic polyisocyanate and a polyol using a known method such as a one-shot method or a prepolymer method.

Examples of the aromatic polyisocyanate include aromatic diisocyanates having 6 to 20 carbon atoms (excluding carbon in the NCO group, the same shall apply hereinafter), modified products of these aromatic diisocyanates (carbodiimide groups, uretdione groups, uretoimine groups, urea groups). And the like, and mixtures of two or more thereof.

Examples of the aromatic polyisocyanate include 1,3- and / or 1,4-phenylene diisocyanate, 2,4- and / or 2,6-tolylene diisocyanate, 2,4′- and / or 4,4′-. Examples include diphenylmethane diisocyanate (hereinafter abbreviated as MDI), 4,4′-diisocyanatobiphenyl, 3,3′-dimethyl-4,4′-diisocyanatodiphenylmethane, 1,5-naphthylene diisocyanate, and the like. Of these, MDI is particularly preferable.

Examples of the polyol include polyether-based, polyester-based, polycarbonate-based, and aliphatic-based polyols, and polyether-based or polyester-based polyols are particularly preferable.
The number average molecular weight of the polyol is preferably 300 or more, more preferably 1000 or more, still more preferably 2000 or more, preferably 4000 or less, more preferably 3500 or less, and still more preferably 3000 or less, from the viewpoint of elasticity.

The brush base tape is made of a material having a 1/2 method melting temperature [T _1/2 ] lower than that of the brush fiber yarn.
Thereby, it becomes possible to melt only the brush base tape in the process described later. If the 1/2 method melting temperature [T _1/2 ] is higher than that of the yarn for brush fibers, the yarn for brush fibers is also melted, and a desired brush may not be manufactured.

The brush substrate tape preferably has a _1/2 method melting temperature [T _1/2 ] of 100 to 200 ° C. If the 1/2 method melting temperature [T _1/2 ] is lower than 100 ° C., the temperature may be higher than 90 ° C. depending on the storage environment of the brush. If the above-mentioned 1/2 method melting temperature [T _1/2 ] exceeds 200 ° C., special heat-resistant parts are required in the production apparatus, or the physical properties and dimensions of the brush fibers tend to be adversely affected in the production stage. It is not preferable. The more preferable range of the 1/2 method melting temperature of the brush substrate tape is 100 to 180 ° C, and more preferably 100 to 160 ° C.
The 1/2 method melting temperature is conventionally used for measuring temperature characteristics in many fields as a standard for evaluating the melting characteristics of a sample in a temperature rising method using a flow tester.
The 1/2 method melting temperature can be measured by a constant load extrusion type capillary rheometer (flow tester). As a specific measurement method, a 2 cm ³ sample was preheated at 80 ° C. for 180 seconds using a flow tester (manufactured by Shimadzu Corporation, CFT-100D), and then at a rate of 6.0 ° C./min. While raising the temperature, the piston pressure was 5.884 × 10 ⁵ Pa and measurement was performed by extruding from a die (hole diameter: 1.0 mm, hole straight portion length: 2.0 mm). FIG. 6 schematically shows a flow curve obtained by measurement with a flow tester, with the horizontal axis representing temperature and the vertical axis representing piston stroke. In the flowable curve, determine the half of the value X of the difference between the flow ending point _{S max} and the lowest point _{S min ((X = S max} -S min) / 2), points were added X and _{S min} A The temperature at the position is the 1/2 method melting temperature.

In the present invention, a step of heating the brush base tape and then fusing it to the brush fiber yarn is then performed.
Although the temperature at the time of performing the fusion is determined according to the type of brush base tape to be used, it is not particularly limited, but is preferably 120 to 200 ° C. A more preferable range of the temperature is 120 to 190 ° C, more preferably 120 to 180 ° C. By setting the temperature at the time of performing the above-mentioned fusion within the above range, it becomes possible to fuse firmly without adversely affecting the physical properties and dimensions of the brush fibers.

In the present invention, the step of alternately folding the brush fiber yarns is then performed.
Examples of the method for alternately folding the yarns for brush fibers include a method of gripping both ends of a base tape and overlapping with adjacent base tapes, or a thin metal rod between adjacent base tapes. For example, a method of arranging and manipulating them to superimpose the tape for base material.

Next, in the present invention, while the brush base tape is heated, the brush base tape is laminated by pressing in the horizontal direction, and the brush base tape is fused.
By performing such a process, it becomes possible to fuse the brush base tapes to each other and raise the brush fiber yarns at the same time.
Then, the process of cutting the said yarn for brush fibers is performed as needed.

In the said process, since the temperature at the time of heating is determined according to the kind of brush base tape to be used, it is not specifically limited, However, 120-200 degreeC is preferable. A more preferable range of the temperature is 120 to 190 ° C, more preferably 120 to 180 ° C. By setting the temperature at the time of the heating within the above range, it becomes possible to fuse firmly without adversely affecting the physical properties and dimensions of the brush fibers.

Since the pressure at the time of pressurizing in the horizontal direction is determined according to the type of brush base tape to be used, it is not particularly limited, but is preferably 100 to 10,000 Pa. By setting the pressure applied in the horizontal direction within the above range, the entire brush can be integrated without being deformed.

In the present invention, finally, a step of cutting the center in the thickness direction of the brush base tape in the horizontal direction is performed. Thereby, the brush which has a brush base and brush fiber is producible.

Examples of the method for cutting the center in the thickness direction of the brush base tape in the horizontal direction include a method of cutting using a cutter, a method of cutting using a wire, and the like.

By using the method for manufacturing a brush according to the present invention, compared to a conventional method for manufacturing a brush, the fiber density of brush fibers can be increased and a brush that can be reliably fixed to a support shaft is manufactured. be able to. Such a brush is also one aspect of the present invention.

The brush of the present invention has a brush base and brush fibers.

The length of the brush fibers is preferably 2 to 30 mm. If the length of the brush fiber is less than 2 mm, it is difficult to obtain uniform contact with the object to be brushed using the elasticity of the fiber. When the length of the brush fiber exceeds 30 mm, it is difficult to obtain a brushing effect utilizing the rebound resilience of the fiber, and there is a tendency that the settling of the fiber due to continuous use tends to be accelerated, which is not preferable. By setting the length of the brush fibers within the above range, the brush has excellent uniform contact by brushing.

Furthermore, the fiber density of the brush fiber is preferably 10,000 to 200,000 pieces / cm ² . By making the fiber density of the brush fiber within the above range, the uniform contact between the brush and the brushing object is less affected by the positional accuracy between the brush and the brushing object, and the uniform contact is possible regardless of the assembly accuracy. An excellent brush.

The shape of the brush of the present invention is not particularly limited, but it is preferable that the brush base has a cylindrical shape and has brush fibers on the cylindrical outer surface of the brush base. By having such a shape, it becomes easy to adapt to the main shafts of various diameters, and fixing to the main shaft by heat treatment becomes easy.

The brush of the present invention can be suitably used as a cleaning brush. It can also be used for applications that require brushing and polishing. Furthermore, it can be used suitably also for a charging brush and a static elimination brush.

By using the brush manufacturing method of the present invention, the fiber density of the brush fibers can be increased and the work efficiency of brush production can be greatly improved as compared with the conventional brush manufacturing method. For example, when the brush of the present invention is used for a cleaning brush, a charging brush, a static elimination brush, a transfer brush, etc., it has excellent performance such as cleaning property and charging property.

It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is drawing which shows typically an example of the manufacturing method of the brush of this invention. It is a graph which shows the flow curve obtained by the measurement of a flow tester.

Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

Example 1
After warping a polyester yarn (Shappe span # 90, _1/2 method melting temperature [T _1/2 ] 255 ° C.) at a warping density of 20 yarns / 12 mm, as shown in FIG. Polyurethane tape (width 6 mm, thickness 50 μm, _1/2 method melting temperature [T _1/2 ] 105 ° C., tensile elongation 100%) was affixed every 3 cm. Next, the polyurethane tape was gently fused with a non-adhesive processing mold heated to 180 ° C.
The tensile elongation was measured by a method based on JIS K 7311.
Thereafter, the warped cotton yarn was alternately folded, and the polyurethane tape was laminated in the horizontal direction while heating at 180 ° C.
After cutting the folded cotton yarn, the center part of the polyurethane tape in the thickness direction was center-cut to produce a brush.
The obtained brush had a fiber density of 100,000 / cm ² and a brush hair length of 13 mm. The brush base had a thickness of 2 mm, a width of 12 mm, and a length of 20 mm.

(Example 2)
Instead of polyester yarn (Shappe span # 90, _1/2 method melting temperature [T _1/2 ] 255 ° C.), conductive nylon fiber (Bertron, KB Selen, 88 dtex / 12f, 1/2 method melting) A brush was produced in the same manner as in Example 1 except that the temperature was 220 ° C.
The obtained brush had a fiber density of 125,000 fibers / cm ² and a brush hair length of 12 mm. The brush base had a thickness of 2 mm, a width of 12 mm, and a length of 20 mm.

(Comparative Example 1)
In place of the polyurethane tape, a brush was prepared in the same manner as in Example 1 except that a polyethylene tape (width 6 mm, thickness 50 μm, _1/2 method melting temperature [T _1/2 ] 105 ° C., tensile elongation 15%) was used. Produced.
The obtained brush had a fiber density of 120,000 fibers / cm ² and a brush hair length of 12 mm. The brush base had a thickness of 2 mm, a width of 12 mm, and a length of 20 mm.

(Comparative Example 2)
In the same manner as in Example 2, after adjusting the diameter of conductive nylon fibers (Bertron, KB Selen, 88 dtex / 12f, 1/2 method melting temperature 220 ° C.), the drawer holding means, the pressing means, the bending A polyurethane sheet (thickness: 2 mm, thickness: 2 mm, using a flocking device having an adhesion guide (the same device as in FIG. 6 of JP-A-6-305088, using a 1 mm thick flat plate as a pressing means)) After the conductive nylon fiber is bent and pressed at a 1/2 method melting temperature [T _1/2 ] 105 ° C.), the length of the bristle is cut so as to be 12 mm. Fiber was planted.
In addition, the obtained brush had a fiber density of 50,000 fibers / cm ² .

(Evaluation)
(1) Mountability to a spindle After cutting out the brush obtained in Example 2 with a width of 47.5 mm and preheating both ends thereof with a non-adhesive processing mold heated to 180 ° C., an outer diameter of 15.5 mm The both ends were fused to each other while being wound around a SUS304 shaft to obtain a brush-coated roll body.

As a result, the brush-coated roll body produced from the brush obtained in Example 2 could be easily coated. In addition, the brush and the SUS shaft were firmly fixed by performing a heat treatment at 120 ° C. for 5 minutes and cooling to room temperature.

On the other hand, the brush obtained in Comparative Example 1 was cut out to a width of 47.5 mm, and both ends thereof were preheated with a non-adhesive processing mold heated to 180 ° C., and then applied to a SUS304 shaft having an outer diameter of 15.5 mm. While winding, the both ends were fused to each other to try to obtain a brush-coated roll body, but the brush was difficult to stretch, it was difficult to butt both ends, and could not be attached to the SUS shaft. .

ADVANTAGE OF THE INVENTION According to this invention, the fiber density of a brush fiber can be raised significantly and the manufacturing method of the brush which can improve the production efficiency at the time of manufacturing a brush, and the manufacturing method of this brush are used. Can be provided.

Claims (3)

Warping the yarn for brush fibers,
A step of applying a brush base tape in a vertical direction of the warped yarn for a brush fiber;
Heating the brush base tape and fusing it to the brush fiber yarn;
A step of alternately folding the yarns for brush fibers,
While heating the brush base tape, pressurizing in the horizontal direction to laminate the brush base tape, and fusing the brush base tape together, and
Having a step of horizontally cutting the center in the thickness direction of the brush base tape,
The brush base tape is made of a stretchable elastic elastomer resin having a tensile elongation of 100 to 900%, and made of a material having a 1/2 method melting temperature lower than that of the yarn for brush fibers. Manufacturing method. 2. The method for producing a brush according to claim 1, wherein the elastic elastic elastomer resin is a polyurethane elastomer. The brush manufactured using the manufacturing method of the brush of Claim 1 or 2.

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