JP5596769B2 - Nonwoven fabric molding production equipment - Google Patents

Nonwoven fabric molding production equipment Download PDF

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JP5596769B2
JP5596769B2 JP2012244646A JP2012244646A JP5596769B2 JP 5596769 B2 JP5596769 B2 JP 5596769B2 JP 2012244646 A JP2012244646 A JP 2012244646A JP 2012244646 A JP2012244646 A JP 2012244646A JP 5596769 B2 JP5596769 B2 JP 5596769B2
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nonwoven fabric
molded product
web
molding surface
fluid
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JP2014091893A (en
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利幸 柳本
善弘 柳本
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Taiyo Machinery Manufacturing Co., Ltd
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Taiyo Machinery Manufacturing Co., Ltd
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Priority to JP2012244646A priority Critical patent/JP5596769B2/en
Priority to PCT/JP2013/069422 priority patent/WO2014073244A1/en
Priority to EP13853599.2A priority patent/EP2918717A4/en
Priority to CN201380057780.7A priority patent/CN104769174B/en
Priority to US14/440,536 priority patent/US20150299920A1/en
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/76—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres otherwise than in a plane, e.g. in a tubular way
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H18/00—Needling machines
    • D04H18/04—Needling machines with water jets

Description

この発明は、例えば、マスク、フィルター、車のシートに用いられるウレタンの補強材などの三次元形状を有する不織布成型品を製造する装置に関する。 The present invention, for example, relates mask, filter, the equipment for producing a non-woven fabric molded article having a three-dimensional shape, such as reinforcement of urethane used in car seat.

従来、不織布成型品の製造装置としては、特開平１１−３１５４５８号公報（特許文献１）に記載されたものがある。この製造装置は、雄金型と雌金型とを備え、この雄、雌金型で不織布をプレス成型して、不織布成型品を製造している。   Conventionally, as a manufacturing apparatus of a nonwoven fabric molded product, there is one described in JP-A-11-315458 (Patent Document 1). This manufacturing apparatus includes a male mold and a female mold, and presses a nonwoven fabric with the male and female molds to manufacture a nonwoven fabric molded product.

ここで、上記不織布の製造について説明すると、一般的に、交絡前の不織布ウェブを、熱ロールの間を通して熱圧着することによって、交絡され圧縮された不織布が、製造される。   Here, the production of the nonwoven fabric will be described. Generally, a nonwoven web that is entangled and compressed is produced by thermocompression bonding of a nonwoven web before entanglement through a hot roll.

特開平１１−３１５４５８号公報JP 11-315458 A

ところで、上記従来の不織布成型品の製造装置を実際に使用すると、次のような問題がある。   By the way, when the conventional apparatus for manufacturing a non-woven fabric molded product is actually used, there are the following problems.

上記不織布から上記不織布成型品を製造するには、予め、不織布ウェブから不織布を製造しなければならない。このように、不織布ウェブから不織布を製造する工程と、不織布から不織布成型品を製造する工程とが、必要になって、製造時間が長く、製造コストが高くなる。   In order to produce the nonwoven fabric molded product from the nonwoven fabric, the nonwoven fabric must be produced in advance from a nonwoven web. Thus, the process of manufacturing a nonwoven fabric from a nonwoven fabric web and the process of manufacturing a nonwoven fabric molded product from a nonwoven fabric are needed, and manufacturing time is long and manufacturing cost becomes high.

また、上記雄、雌金型のプレスにより、不織布から不織布成型品を製造するので、不織布成型品の形状を変更する場合、雄、雌金型を変える必要があり、金型の数量が多くなる。   In addition, since the non-woven fabric molded product is manufactured from the non-woven fabric by pressing the male and female dies, it is necessary to change the male and female dies when changing the shape of the non-woven fabric molded product, and the number of dies increases. .

また、上記不織布から上記不織布成型品を製造するので、不織布成型品の製造において余分な部分は、不織布の状態で取り除かれる。このように、余分な部分は、熱処理によって圧縮された状態であるため、この余分な部分を再利用することは困難である。この余分な部分は、製品によっては、全体の４割となることもある。したがって、資源の無駄となり、環境に悪い。   Moreover, since the said nonwoven fabric molded product is manufactured from the said nonwoven fabric, an excess part is removed in the state of a nonwoven fabric in manufacture of a nonwoven fabric molded product. Thus, since the extra portion is compressed by the heat treatment, it is difficult to reuse the extra portion. This extra portion may be 40% of the total depending on the product. Therefore, resources are wasted and bad for the environment.

また、上記不織布では、部分的に、密度（目付）や、繊維同士の交絡度や、厚みを変更することができず、この不織布から製造する不織布成型品も、部分的に、密度、交絡度、厚みを変更することができない。このため、不織布成型品を、部分的に、密度、交絡度または厚みを、大きくしたくても、不織布成型品の全体を大きくしなければならず、資源の無駄となり、環境に悪い。   Moreover, in the said nonwoven fabric, a density (weight per unit area), the entanglement degree of fibers, and thickness cannot be changed, and the nonwoven fabric molded product manufactured from this nonwoven fabric also partially has density, entanglement degree. The thickness cannot be changed. For this reason, even if it is desired to partially increase the density, the entanglement degree, or the thickness of the nonwoven fabric molded product, the entire nonwoven fabric molded product must be enlarged, resulting in waste of resources and being bad for the environment.

そこで、この発明の課題は、製造時間や製造コストを低減し、金型の数量を少なくし、資源の無駄を減らして環境に優れたものとなる不織布成型品の製造装置を提供することにある。 Accordingly, an object of the present invention is to reduce manufacturing time and manufacturing cost, to reduce the quantity of molds, to reduce the waste of resources to provide a manufacturing equipment of the non-woven fabric molded article becomes excellent in environmental is there.

上記課題を解決するため、この発明の不織布成型品の製造装置は、
三次元形状の成型面を有し、上記成型面には、流体を通過させるための複数の貫通孔が設けられ、上記成型面は、上面および側面を含む成型金型と、
流体を上記成型面の上面および側面に向けて上記成型面上に載置された交絡前の不織布ウェブに吹き付けて上記不織布ウェブを上記成型面に押し付け、上記不織布ウェブの繊維同士を交絡させると共に上記不織布ウェブを上記成型面の三次元形状に沿うように成型して、三次元形状の不織布成型品を製造する流体吹き付け手段と
を備えることを特徴としている。 In order to solve the above problems, the nonwoven fabric molded product manufacturing apparatus of the present invention comprises:
Have a molding surface of the three-dimensional shape, the above-mentioned molding surface, a plurality of through holes for passing the fluid is provided, the molding surface has a molding die including upper and side surfaces,
Fluid toward the upper surface and side surfaces of the molding surface pressing on the Symbol nonwoven web to the molding surface put come blown nonwoven web before entangled placed on the molding surface, entangling fibers of the nonwoven web When is the upper Symbol nonwoven web co by molding along the three-dimensional shape of the molding surface, is characterized by comprising a fluid blowing means for producing a non-woven fabric molded three-dimensional shape.

ここで、流体とは、例えば、水等の液体や蒸気等の気体であり、不織布ウェブを交絡させる程度の高い圧力を有する。例えば、流体が水である場合、流体の圧力は、１０ＭＰａ〜２０ＭＰａである。もちろん、この圧力は、不織布成型品の厚みや硬度等によって、変更可能である。   Here, the fluid is, for example, a liquid such as water or a gas such as steam, and has a high pressure to entangle the nonwoven web. For example, when the fluid is water, the pressure of the fluid is 10 MPa to 20 MPa. Of course, this pressure can be changed depending on the thickness and hardness of the nonwoven fabric molded product.

この発明の不織布成型品の製造装置によれば、不織布ウェブから三次元形状の成型と交絡とを同時に一気に行うことができるので、従来の不織布ウェブから不織布を製造する交絡工程を、省くことができて、工程が簡素になって、安価に不織布成型品を製造できる。   According to the apparatus for producing a nonwoven fabric molded product of the present invention, since a three-dimensional shape can be simultaneously formed and entangled from a nonwoven fabric web, the entanglement process for producing a nonwoven fabric from a conventional nonwoven fabric web can be omitted. Thus, the process is simplified, and a non-woven fabric molded product can be manufactured at a low cost.

また、流体吹き付け手段の流体で不織布ウェブを成型金型に押し付けるので、流体吹き付け手段が、従来のプレス成型に用いられる雄金型と雌金型の一方の金型の役割を担い、この一方の金型を省略できる。これにより、不織布成型品の形状を変える場合、他方の金型を変えるだけでよく、金型の数量を低減できる。   Moreover, since the nonwoven fabric web is pressed against the molding die by the fluid of the fluid spraying means, the fluid spraying means plays the role of one of the male mold and the female mold used in conventional press molding. The mold can be omitted. Thereby, when changing the shape of a nonwoven fabric molded product, it is only necessary to change the other mold, and the number of molds can be reduced.

また、不織布ウェブから流体によって不織布成型品を製造するので、不織布成型品の製造において余分な材料は、流体によって、不織布ウェブからそのままの状態で取り除かれ、この余分な材料をそのまま再利用できる。したがって、資源の無駄を減らし、環境に優れたものとなる。   Moreover, since a nonwoven fabric molded product is manufactured from a nonwoven fabric web by a fluid, an excess material in manufacture of a nonwoven fabric molded product is removed from a nonwoven fabric web by a fluid as it is, and this excess material can be reused as it is. Therefore, waste of resources is reduced and the environment is excellent.

また、従来の不織布では、部分的に、密度（目付）を変更することができなかったが、本発明では、不織布ウェブの状態で余分な材料を必要な部分に重ね合わせてから、不織布成型品を製造することが可能である。これにより、本発明では、従来の不織布からの成型品に比べて、原料を少なくすることが可能になって、環境に良い。   Further, in the conventional nonwoven fabric, the density (weight per unit area) could not be partially changed. However, in the present invention, the nonwoven fabric molded product is obtained after superimposing an unnecessary material on the necessary portion in the nonwoven fabric web state. Can be manufactured. Thereby, in this invention, compared with the molded article from the conventional nonwoven fabric, it becomes possible to reduce a raw material and is good for an environment.

また、従来の不織布では、部分的に、繊維同士の交絡度や厚みを変更することができなかったが、本発明では、不織布ウェブに吹き付ける流体の圧力、距離、時間、角度を変更することで、不織布成型品を、部分的に、交絡度や厚みを変更することができる。これにより、本発明では、不織布成型品の（交絡度や厚みに起因する）機能を、最小限の原料でもたらすことができて、環境に良い。   Moreover, in the conventional nonwoven fabric, the entanglement degree and thickness of fibers could not be partially changed, but in the present invention, the pressure, distance, time, and angle of the fluid sprayed on the nonwoven fabric web can be changed. The degree of entanglement and the thickness of the nonwoven fabric molded product can be partially changed. Thereby, in this invention, the function (it originates in an entanglement degree and thickness) of a nonwoven fabric molded product can be brought about with the minimum raw material, and it is good for an environment.

また、不織布ウェブに吹き付けられた後の流体は、成型金型の成型面の貫通孔を通過する。これにより、不織布ウェブを通過した流体が成型面に当たってはね返ることを防止して、不織布ウェブを成型面に確実に押し付けることができて、不織布ウェブから三次元形状の成型と交絡とを確実に行うことができる。 Moreover , the fluid after being sprayed on the nonwoven fabric web passes through the through hole of the molding surface of the molding die. This prevents the fluid that has passed through the nonwoven web from hitting the molding surface and rebounding it, so that the nonwoven web can be reliably pressed against the molding surface, and the molding and entanglement of the three-dimensional shape from the nonwoven web can be performed reliably. Can do.

また、一実施形態の不織布成型品の製造装置では、
上記成型金型は、上記成型面に突起部を有し、
上記流体吹き付け手段は、上記不織布ウェブに上記流体を吹き付けて、上記不織布ウェブを上記突起部に沿うように成型する。 Moreover, in the manufacturing apparatus of the nonwoven fabric molded product of one embodiment,
The molding die has a protrusion on the molding surface,
The fluid spraying means sprays the fluid onto the non-woven web and molds the non-woven web along the protrusions .

この実施形態の不織布成型品の製造装置によれば、流体吹き付け手段は、上記不織布ウェブに上記流体を吹き付けて、上記不織布ウェブを上記突起部に沿うように成型する。これにより、不織布ウェブに突起部に対応する位置に孔や溝を形成することができる。 According to the non-woven fabric molded product manufacturing apparatus of this embodiment, the fluid spraying means sprays the fluid onto the non-woven web and molds the non-woven web along the protrusions . Thereby , a hole and a groove | channel can be formed in the position corresponding to a projection part in a nonwoven fabric web.

また、一実施形態の不織布成型品の製造装置では、上記流体吹き付け手段は、上記不織布ウェブの同一部分に異なる方向から流体を噴出する複数のノズルを有する。   Moreover, in the manufacturing apparatus of the nonwoven fabric molded product of one Embodiment, the said fluid spraying means has several nozzles which eject a fluid from a different direction to the same part of the said nonwoven fabric web.

この実施形態の不織布成型品の製造装置によれば、上記複数のノズルは、互いに異なる方向から、不織布ウェブの同一部分に流体を噴出する。これにより、不織布ウェブの繊維同士の交絡をより複雑かつ確実にでき、不織布成型品の強度を向上できる。   According to the apparatus for manufacturing a nonwoven fabric molded product of this embodiment, the plurality of nozzles eject fluid from the different directions to the same portion of the nonwoven fabric web. Thereby, the entanglement of the fibers of the nonwoven web can be made more complicated and reliable, and the strength of the nonwoven fabric molded product can be improved.

また、一実施形態の不織布成型品の製造装置では、上記流体吹き付け手段は、上記不織布ウェブに吹き付ける流体の圧力、距離、時間、角度の少なくとも一つを変更可能である。 Moreover, in the manufacturing apparatus of the nonwoven fabric molded product of one Embodiment, the said fluid spraying means can change at least one of the pressure of the fluid sprayed on the said nonwoven fabric web, distance, time, and an angle.

この実施形態の不織布成型品の製造装置によれば、従来の不織布では、部分的に、繊維同士の交絡度や厚みを変更することができなかったが、本発明では、不織布ウェブに吹き付ける流体の圧力、距離、時間、角度を変更することで、不織布成型品を、部分的に、交絡度や厚みを変更することができる。これにより、本発明では、不織布成型品の（交絡度や厚みに起因する）機能を、最小限の原料でもたらすことができて、環境に良い。According to the apparatus for producing a nonwoven fabric molded product of this embodiment, in the conventional nonwoven fabric, the entanglement degree and thickness of the fibers could not be partially changed. By changing the pressure, distance, time, and angle, the degree of entanglement and thickness of the nonwoven fabric molded product can be partially changed. Thereby, in this invention, the function (it originates in an entanglement degree and thickness) of a nonwoven fabric molded product can be brought about with the minimum raw material, and it is good for an environment.

また、一実施形態の不織布成型品の製造装置では、上記不織布ウェブとして、一の繊維材料に部分的に他の繊維材料を重ね合わせたものを用いる。Moreover, in the manufacturing apparatus of the nonwoven fabric molded article of one Embodiment, what overlap | superposed the other fiber material partially on one fiber material is used as the said nonwoven fabric web.

この実施形態の不織布成型品の製造装置によれば、従来の不織布では、部分的に、密度（目付）を変更することができなかったが、本発明では、不織布ウェブの状態で余分な材料を必要な部分に重ね合わせてから、不織布成型品を製造することが可能である。これにより、本発明では、従来の不織布からの成型品に比べて、原料を少なくすることが可能になって、環境に良い。According to the apparatus for producing a nonwoven fabric molded product of this embodiment, the density (weight per unit area) could not be partially changed in the conventional nonwoven fabric, but in the present invention, an extra material is added in the state of the nonwoven fabric web. It is possible to manufacture a non-woven fabric molded product after being superimposed on a necessary portion. Thereby, in this invention, compared with the molded article from the conventional nonwoven fabric, it becomes possible to reduce a raw material and is good for an environment.

この発明の不織布成型品の製造装置によれば、成型金型と流体吹き付け手段とを備えるので、不織布ウェブから流体によって不織布成型品を製造でき、製造時間や製造コストを低減し、金型の数量を少なくし、資源の無駄を減らして環境に優れたものとなる。   According to the nonwoven fabric molded product manufacturing apparatus of the present invention, since the molding die and the fluid spraying means are provided, the nonwoven fabric molded product can be manufactured by fluid from the nonwoven fabric web, the manufacturing time and manufacturing cost can be reduced, and the number of molds can be reduced. This reduces the waste of resources and makes the environment better.

本発明の第１実施形態の不織布成型品の製造装置を示す簡略構成図である。BRIEF DESCRIPTION OF THE DRAWINGS It is a simple block diagram which shows the manufacturing apparatus of the nonwoven fabric molded product of 1st Embodiment of this invention. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 不織布成型品の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a nonwoven fabric molded product. 本発明の第２実施形態の不織布成型品の製造装置を示す簡略構成図である。It is a simplified block diagram which shows the manufacturing apparatus of the nonwoven fabric molded product of 2nd Embodiment of this invention. 他の不織布成型品の製造装置を示す簡略構成図である。It is a simplified block diagram which shows the manufacturing apparatus of another nonwoven fabric molded article.

以下、この発明を図示の実施の形態により詳細に説明する。   Hereinafter, the present invention will be described in detail with reference to the illustrated embodiments.

（第１の実施形態）
図１は、この発明の第１実施形態の不織布成型品の製造装置を示す簡略構成図である。図１に示すように、この製造装置は、三次元形状の成型面１０を有する成型金型１と、上記成型金型１の成型面１０に水を吹き付けるウォータジェット２とを備える。ウォータジェット２は、流体吹き付け手段の一例である。 (First embodiment)
FIG. 1 is a simplified configuration diagram showing an apparatus for manufacturing a nonwoven fabric molded product according to a first embodiment of the present invention. As shown in FIG. 1, the manufacturing apparatus includes a molding die 1 having a three-dimensional molding surface 10 and a water jet 2 that sprays water onto the molding surface 10 of the molding die 1. The water jet 2 is an example of a fluid spraying unit.

上記成型金型１の上記成型面１０は、４つの側面と１つの上面とを含む５面体から構成されている。この成型面１０には、複数の貫通孔１１が設けられ、この貫通孔１１は、ウォータジェット２から吹き付けられる水を通過させる。この成型面１０は、例えば、金網によって形成される。   The molding surface 10 of the molding die 1 is composed of a pentahedron including four side surfaces and one upper surface. The molding surface 10 is provided with a plurality of through holes 11 through which water blown from the water jet 2 passes. The molding surface 10 is formed by, for example, a wire mesh.

上記成型面１０の上面には、ピン形状の位置決め用突起部１２と、箱形状の孔形成用突起部１３が設けられている。上記成型面１０の１つの側面には、滑り台形状の溝形成用突起部１４が設けられている。   On the upper surface of the molding surface 10, a pin-shaped positioning projection 12 and a box-shaped projection 13 for hole formation are provided. On one side surface of the molding surface 10, a slide-shaped groove forming projection 14 is provided.

上記ウォータジェット２は、門型の本体部２０と、この本体部２０に設けられた複数のノズル２１とを有する。このノズル２１の噴出孔２１ａは、門型の本体部２０の内側を向く３つの面に、設けられている。   The water jet 2 has a gate-shaped main body 20 and a plurality of nozzles 21 provided in the main body 20. The ejection holes 21 a of the nozzle 21 are provided on three surfaces facing the inside of the gate-shaped main body 20.

上記ウォータジェット２は、上記成型金型１を跨ぐことができる大きさに、設定されている。成型金型１は、ウォータジェット２に対して、相対的に接近または離隔可能となる。つまり、成型金型１の成型面１０の全領域に、順に、ノズル２１の噴出孔２１ａを対向させ、この噴出孔２１ａから水を吹き付けることができる。この水の圧力は、後述の不織布ウェブ３を交絡させる程度の高い圧力であり、例えば、１０ＭＰａ〜２０ＭＰａである。   The water jet 2 is set to a size that can straddle the molding die 1. The molding die 1 can be relatively approached or separated from the water jet 2. That is, the ejection hole 21a of the nozzle 21 can be made to face the entire region of the molding surface 10 of the molding die 1 in order, and water can be sprayed from the ejection hole 21a. The water pressure is high enough to entangle the nonwoven fabric web 3 described later, and is, for example, 10 MPa to 20 MPa.

次に、上記構成の製造装置を用いて、不織布ウェブ３から不織布成型品５を製造する方法を説明する。   Next, a method of manufacturing the nonwoven fabric molded product 5 from the nonwoven fabric web 3 using the manufacturing apparatus having the above configuration will be described.

まず、図２Ａに示すように、複数の繊維を積層して、不織布ウェブ３を製造する。この不織布ウェブ３の製造には、従来より既知の方法（乾式法や湿式法など）を用いる。繊維は、例えば、ポリエステルからなる。不織布ウェブ３は、繊維同士が交絡される前のものであり、フリースとも呼ばれる。ここで、繊維同士の交絡とは、繊維同士を結合させ絡ませることである。   First, as shown in FIG. 2A, a plurality of fibers are laminated to produce a nonwoven fabric web 3. For the production of the nonwoven web 3, a conventionally known method (such as a dry method or a wet method) is used. The fiber is made of polyester, for example. The nonwoven web 3 is before the fibers are entangled and is also called a fleece. Here, the entanglement between the fibers means that the fibers are bound and entangled.

その後、図２Ｂに示すように、上記不織布ウェブ３の予め定められた位置に、十字状のスリット３０と、貫通する孔部３１とを、加工する。このスリット３０の位置は、上記成型金型１の位置決め用突起部１２の位置に対応し、この孔部３１の位置は、上記成型金型１の孔形成用突起部１３の位置に対応する。   Thereafter, as shown in FIG. 2B, the cross-shaped slit 30 and the penetrating hole 31 are processed at predetermined positions of the nonwoven fabric web 3. The position of the slit 30 corresponds to the position of the positioning protrusion 12 of the molding die 1, and the position of the hole 31 corresponds to the position of the hole forming protrusion 13 of the molding die 1.

その後、図２Ｃに示すように、上記交絡前の不織布ウェブ３を、不織布ウェブ３の一面が上記成型金型１の成型面１０に対向するように、上記成型面１０上に載置する。すると、図２Ｄに示すように、不織布ウェブ３のスリット３０に、成型金型１の位置決め用突起部１２が突き刺され、不織布ウェブ３の孔部３１に、成型金型１の孔形成用突起部１３が嵌め込まれる。このとき、位置決め用突起部１２の先端は、不織布ウェブ３から露出していないが、スリット３０から露出するようにしてもよい。   Thereafter, as shown in FIG. 2C, the nonwoven web 3 before entanglement is placed on the molding surface 10 so that one surface of the nonwoven fabric web 3 faces the molding surface 10 of the molding die 1. Then, as shown in FIG. 2D, the positioning projection 12 of the molding die 1 is pierced into the slit 30 of the nonwoven fabric web 3, and the hole forming projection of the molding die 1 is inserted into the hole 31 of the nonwoven fabric web 3. 13 is fitted. At this time, the tip of the positioning projection 12 is not exposed from the nonwoven web 3 but may be exposed from the slit 30.

その後、上記成型面１０に載置された上記不織布ウェブ３を、上記ウォータジェット２内に、移動させる。そして、ウォータジェット２から、不織布ウェブ３の他面に水を吹き付ける。   Thereafter, the nonwoven web 3 placed on the molding surface 10 is moved into the water jet 2. Then, water is sprayed from the water jet 2 to the other surface of the nonwoven fabric web 3.

こうすることにより、図２Ｅに示すように、上記不織布ウェブ３を上記成型面１０に押し付け、不織布ウェブ３の繊維３２同士を交絡させると共に、不織布ウェブ３を成型面１０の三次元形状に沿うように成型する。図中、成型面１０を、ノズル２１に対して、左から右へ移動するものとする。   By doing so, as shown in FIG. 2E, the nonwoven web 3 is pressed against the molding surface 10 so that the fibers 32 of the nonwoven web 3 are entangled with each other, and the nonwoven web 3 is conformed to the three-dimensional shape of the molding surface 10. To mold. In the figure, the molding surface 10 is moved from the left to the right with respect to the nozzle 21.

このとき、上記不織布ウェブ３に吹き付けられた後の水は、成型面１０の貫通孔１１を通過する。これにより、不織布ウェブ３を通過した水が成型面１０に当たってはね返ることを防止して、不織布ウェブ３を成型面１０に確実に押し付けることができて、不織布ウェブ３から三次元形状の成型と交絡とを確実に行うことができる。   At this time, the water after being sprayed on the nonwoven fabric web 3 passes through the through hole 11 of the molding surface 10. This prevents the water that has passed through the nonwoven fabric web 3 from hitting the molding surface 10 and splashing it back, so that the nonwoven fabric web 3 can be reliably pressed against the molding surface 10. Can be performed reliably.

また、図２Ｆに示すように、上記位置決め用突起部１２に突き刺された不織布ウェブ３に、ウォータジェット２から水を吹き付けて、不織布ウェブ３に位置決め用突起部１２を貫通させ、不織布ウェブ３を位置決め用突起部１２に係止させて位置決めする。図中、成型面１０を、ノズル２１に対して、左から右へ移動するものとする。これにより、不織布ウェブ３に位置決め用突起部１２を貫通させるための孔を、予め、設ける必要がなく、工程が簡素になり、材料の無駄を削減できる。   Also, as shown in FIG. 2F, water is sprayed from the water jet 2 to the nonwoven web 3 pierced by the positioning protrusions 12, and the nonwoven fabric web 3 is caused to penetrate the positioning protrusions 12, so that the nonwoven web 3 Positioning is performed by engaging the positioning projection 12. In the figure, the molding surface 10 is moved from the left to the right with respect to the nozzle 21. Thereby, it is not necessary to provide the hole for penetrating the positioning protrusion 12 in the nonwoven fabric web 3 in advance, the process is simplified, and the waste of material can be reduced.

このように、上記不織布ウェブ３から、三次元形状の成型と交絡とを同時に一気に行って、図２Ｇに示すように、不織布成型品５を製造する。この不織布成型品５は、上記成型面１０に沿った三次元形状を有する。   Thus, the nonwoven fabric web 3 is manufactured by simultaneously performing the molding and entanglement of the three-dimensional shape at the same time as shown in FIG. 2G. The nonwoven fabric molded product 5 has a three-dimensional shape along the molding surface 10.

その後、上記成型面１０に載置された不織布成型品５を、乾燥し、冷却して、図２Ｈに示すように、不織布成型品５を、成型金型１から取り外す。この不織布成型品５には、上記位置決め用突起部１２に対応する位置に孔が形成され、上記孔形成用突起部１３に対応する位置に孔が形成され、上記溝形成用突起部１４に対応する位置に溝が形成される。   Thereafter, the nonwoven fabric molded product 5 placed on the molding surface 10 is dried and cooled, and the nonwoven fabric molded product 5 is removed from the molding die 1 as shown in FIG. 2H. In this non-woven fabric molded product 5, a hole is formed at a position corresponding to the positioning protrusion 12, a hole is formed at a position corresponding to the hole forming protrusion 13, and it corresponds to the groove forming protrusion 14. A groove is formed at the position to be.

上記不織布成型品５は、例えば、マスク、フィルター、車のシートに用いられるウレタンの補強材などである。この補強材とは、シートの座面側に配置されるウレタンと、シートの背面側に配置される背面部材との間に、配置されるものであり、ウレタンの剥がれを防止したり、ウレタンと背面部材との擦れ音を防止する。   The nonwoven fabric molded product 5 is, for example, a mask, a filter, a urethane reinforcing material used for a car seat, or the like. This reinforcing material is arranged between the urethane arranged on the seat surface side of the seat and the back member arranged on the back side of the seat, and prevents the urethane from peeling off, Prevents rubbing noise with the back member.

上記構成の不織布成型品の製造装置およびその製造方法によれば、不織布ウェブ３から三次元形状の成型と交絡とを同時に一気に行うことができるので、従来の不織布ウェブ３から不織布を製造する交絡工程を、省くことができて、工程が簡素になって、安価に不織布成型品５を製造できる。   According to the nonwoven fabric molded product manufacturing apparatus and the manufacturing method thereof having the above-described configuration, the three-dimensional shape can be molded and entangled from the nonwoven fabric web 3 at the same time. Can be omitted, the process is simplified, and the nonwoven fabric molded product 5 can be manufactured at a low cost.

また、ウォータジェット２の水で不織布ウェブ３を成型金型１に押し付けるので、ウォータジェット２が、従来のプレス成型に用いられる雄金型と雌金型の一方の金型の役割を担い、この一方の金型を省略できる。これにより、不織布成型品５の形状を変える場合、他方の金型を変えるだけでよく、金型の数量を低減できる。   Moreover, since the nonwoven fabric web 3 is pressed against the mold 1 with the water of the water jet 2, the water jet 2 plays the role of one of the male mold and the female mold used in conventional press molding. One mold can be omitted. Thereby, when changing the shape of the nonwoven fabric molded product 5, it is only necessary to change the other mold, and the number of molds can be reduced.

また、不織布ウェブ３から水によって不織布成型品５を製造するので、不織布成型品５の製造において余分な材料は、水によって、不織布ウェブ３からそのままの状態で取り除かれ、この余分な材料をそのまま再利用できる。したがって、資源の無駄を減らし、環境に優れたものとなる。   Further, since the nonwoven fabric molded product 5 is produced from the nonwoven fabric web 3 with water, excess material in the production of the nonwoven fabric molded product 5 is removed from the nonwoven fabric web 3 as it is with water, and this excess material is reused as it is. Available. Therefore, waste of resources is reduced and the environment is excellent.

また、従来の不織布では、部分的に、密度（目付）を変更することができなかったが、本発明では、不織布ウェブ３の状態で余分な材料を必要な部分に重ね合わせてから、不織布成型品５を製造することが可能である。これにより、本発明では、従来の不織布からの成型品に比べて、原料を少なくすることが可能になって、環境に良い。   Further, in the conventional nonwoven fabric, the density (weight per unit area) could not be partially changed. However, in the present invention, the nonwoven fabric web 3 is overlaid with unnecessary material on the necessary portion, and then the nonwoven fabric molding is performed. Product 5 can be manufactured. Thereby, in this invention, compared with the molded article from the conventional nonwoven fabric, it becomes possible to reduce a raw material and is good for an environment.

また、従来の不織布では、部分的に、繊維同士の交絡度や厚みを変更することができなかったが、本発明では、不織布ウェブ３に吹き付ける水の圧力、距離、時間、角度を変更することで、不織布成型品５を、部分的に、交絡度や厚みを変更することができる。これにより、本発明では、不織布成型品５の（交絡度や厚みに起因する）機能を、最小限の原料でもたらすことができて、環境に良い。   Moreover, in the conventional nonwoven fabric, the entanglement degree and thickness of fibers could not be partially changed, but in the present invention, the pressure, distance, time, and angle of water sprayed on the nonwoven fabric web 3 are changed. Thus, the degree of entanglement and thickness of the nonwoven fabric molded product 5 can be partially changed. Thereby, in this invention, the function (it originates in a entanglement degree and thickness) of the nonwoven fabric molded product 5 can be brought about with the minimum raw material, and it is good for an environment.

（第２の実施形態）
図３Ａ、図３Ｂは、この発明の第２実施形態の不織布成型品の製造装置を示す要部拡大図である。この第２の実施形態は、上記第１の実施形態（図２Ｅ）とは、ノズルの構成のみが相違する。この相違する構成のみを以下に説明する。 (Second Embodiment)
FIG. 3A and FIG. 3B are enlarged views of main parts showing a nonwoven fabric molded product manufacturing apparatus according to a second embodiment of the present invention. This second embodiment is different from the first embodiment (FIG. 2E) only in the configuration of the nozzle. Only this different configuration will be described below.

図３Ａに示すように、第１のノズル２１Ａと第２のノズル２１Ｂは、互いに異なる方向から、不織布ウェブ３の同一部分に水を噴出する。第１のノズル２１Ａの噴出方向は、成型面１０に対して直交する方向である。第２のノズル２１Ｂの噴出方向は、成型面１０に対して４５°傾斜する方向である。   As shown to FIG. 3A, the 1st nozzle 21A and the 2nd nozzle 21B spout water to the same part of the nonwoven fabric web 3 from a mutually different direction. The ejection direction of the first nozzle 21 </ b> A is a direction orthogonal to the molding surface 10. The ejection direction of the second nozzle 21 </ b> B is a direction inclined by 45 ° with respect to the molding surface 10.

これにより、不織布ウェブ３の繊維３２同士の交絡をより複雑かつ確実にでき、不織布成型品５の強度を向上できる。   Thereby, the entanglement of the fibers 32 of the nonwoven fabric web 3 can be made more complicated and reliable, and the strength of the nonwoven fabric molded product 5 can be improved.

なお、図３Ｂに示すように、第１のノズル２１Ａの噴出方向を、第２のノズル２１Ｂの噴出方向と左右対称に、成型面１０に対して１３５°傾斜する方向としてもよい。   As shown in FIG. 3B, the ejection direction of the first nozzle 21 </ b> A may be a direction inclined by 135 ° with respect to the molding surface 10 symmetrically with the ejection direction of the second nozzle 21 </ b> B.

なお、この発明は上述の実施形態に限定されない。例えば、上記第１、上記第２の実施形態のそれぞれの特徴点を様々に組み合わせてもよい。   In addition, this invention is not limited to the above-mentioned embodiment. For example, the feature points of the first and second embodiments may be variously combined.

上記実施形態では、上記流体吹き付け手段として、門型のウォータジェット２を用いたが、部分的に吹き付け可能なロボットアームであってもよい。   In the above embodiment, the gate-type water jet 2 is used as the fluid spraying means. However, a robot arm that can be sprayed partially may be used.

上記実施形態では、流体として、水を用いたが、水以外の液体や、蒸気等の気体であってもよい。流体は、不織布ウェブ３を交絡させる程度の高い圧力を有する。もちろん、この圧力は、不織布成型品５の厚みや硬度等によって、変更可能である。   In the above embodiment, water is used as the fluid. However, a liquid other than water or a gas such as steam may be used. The fluid has a high enough pressure to entangle the nonwoven web 3. Of course, this pressure can be changed depending on the thickness and hardness of the nonwoven fabric molded product 5.

上記実施形態では、上記不織布ウェブ３の同一部分に水を噴出するノズル２１，２１Ａ，２１Ｂの数量を、１つまたは２つとしたが、３つ以上であってもよい。   In the above embodiment, the number of nozzles 21, 21 </ b> A, 21 </ b> B that ejects water to the same portion of the nonwoven fabric web 3 is one or two, but may be three or more.

上記実施形態では、上記成型面１０に、上記貫通孔１１を設けたが、これを省略してもよい。   In the embodiment described above, the through hole 11 is provided in the molding surface 10, but this may be omitted.

上記実施形態では、上記成型面１０に、上記突起部１２，１３，１４を設けたが、これらの少なくとも一つを省略してもよい。   In the above embodiment, the protrusions 12, 13, and 14 are provided on the molding surface 10, but at least one of them may be omitted.

１ 成型金型
１０ 成型面
１１ 貫通孔
１２ 位置決め用突起部
１３ 孔形成用突起部
１４ 溝形成用突起部
２ ウォータジェット（流体吹き付け手段）
２０ 本体部
２１，２１Ａ，２１Ｂ ノズル
２１ａ 噴出孔
３ 不織布ウェブ
３０ スリット
３１ 孔部
３２ 繊維
５ 不織布成型品 DESCRIPTION OF SYMBOLS 1 Molding die 10 Molding surface 11 Through-hole 12 Protrusion part for positioning 13 Protrusion part for hole formation 14 Protrusion part for groove formation 2 Water jet (fluid spraying means)
DESCRIPTION OF SYMBOLS 20 Main body part 21,21A, 21B Nozzle 21a Ejection hole 3 Nonwoven fabric web 30 Slit 31 Hole part 32 Fiber 5 Nonwoven fabric molding

Claims (5)

三次元形状の成型面を有し、上記成型面には、流体を通過させるための複数の貫通孔が設けられ、上記成型面は、上面および側面を含む成型金型と、
流体を上記成型面の上面および側面に向けて上記成型面上に載置された交絡前の不織布ウェブに吹き付けて上記不織布ウェブを上記成型面に押し付け、上記不織布ウェブの繊維同士を交絡させると共に上記不織布ウェブを上記成型面の三次元形状に沿うように成型して、三次元形状の不織布成型品を製造する流体吹き付け手段と
を備えることを特徴とする不織布成型品の製造装置。 Have a molding surface of the three-dimensional shape, the above-mentioned molding surface, a plurality of through holes for passing the fluid is provided, the molding surface has a molding die including upper and side surfaces,
Fluid toward the upper surface and side surfaces of the molding surface pressing on the Symbol nonwoven web to the molding surface put come blown nonwoven web before entangled placed on the molding surface, entangling fibers of the nonwoven web and the upper Symbol nonwoven web and molded to conform to the three-dimensional shape of the molding surface when is the co-production of non-woven moldings, characterized in that it comprises a fluid blowing means for producing a non-woven fabric molded three-dimensional shape apparatus. 請求項１に記載の不織布成型品の製造装置において、
上記成型金型は、上記成型面に突起部を有し、
上記流体吹き付け手段は、上記不織布ウェブに上記流体を吹き付けて、上記不織布ウェブを上記突起部に沿うように成型することを特徴とする不織布成型品の製造装置。 In the manufacturing apparatus of the nonwoven fabric molded product according to claim 1 ,
The molding die has a protrusion on the molding surface,
The said fluid spraying means sprays the said fluid on the said nonwoven fabric web, and shape | molds the said nonwoven fabric web along the said projection part, The manufacturing apparatus of the nonwoven fabric molded product characterized by the above-mentioned . 請求項１または２に記載の不織布成型品の製造装置において、
上記流体吹き付け手段は、上記不織布ウェブの同一部分に異なる方向から流体を噴出する複数のノズルを有することを特徴とする不織布成型品の製造装置。 In the manufacturing apparatus of the nonwoven fabric molded product of Claim 1 or 2 ,
The said fluid spraying means has a several nozzle which ejects a fluid from a different direction to the same part of the said nonwoven fabric web, The manufacturing apparatus of the nonwoven fabric molded product characterized by the above-mentioned. 請求項１から３の何れか一つに記載の不織布成型品の製造装置において、
上記流体吹き付け手段は、上記不織布ウェブに吹き付ける流体の圧力、距離、時間、角度の少なくとも一つを変更可能であることを特徴とする不織布成型品の製造装置。 In the manufacturing apparatus of the nonwoven fabric molded product according to any one of claims 1 to 3,
The said fluid spraying means can change at least one of the pressure of the fluid sprayed on the said nonwoven fabric web , distance, time, and an angle, The manufacturing apparatus of the nonwoven fabric molded product characterized by the above-mentioned. 請求項１から４の何れか一つに記載の不織布成型品の製造装置において、In the manufacturing apparatus of the nonwoven fabric molded product according to any one of claims 1 to 4,
上記不織布ウェブとして、一の繊維材料に部分的に他の繊維材料を重ね合わせたものを用いることを特徴とする不織布成型品の製造装置。An apparatus for producing a non-woven fabric molded product, wherein the non-woven fabric web is one obtained by partially superimposing another fibrous material on one fibrous material.
JP2012244646A 2012-11-06 2012-11-06 Nonwoven fabric molding production equipment Expired - Fee Related JP5596769B2 (en)

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JP2012244646A JP5596769B2 (en) 2012-11-06 2012-11-06 Nonwoven fabric molding production equipment
PCT/JP2013/069422 WO2014073244A1 (en) 2012-11-06 2013-07-17 Device for manufacturing nonwoven fabric molded product and method for manufacturing same
EP13853599.2A EP2918717A4 (en) 2012-11-06 2013-07-17 Device for manufacturing nonwoven fabric molded product and method for manufacturing same
CN201380057780.7A CN104769174B (en) 2012-11-06 2013-07-17 The manufacture device of non-woven fabrics products formed
US14/440,536 US20150299920A1 (en) 2012-11-06 2013-07-17 Device for manufacturing nonwoven fabric molded product and method for manufacturing same

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