JP6683580B2 - Method for manufacturing functional sheet body - Google Patents

Description

  The present invention relates to a method for producing a functional sheet body containing magnetic powder.

  A sheet-shaped heat generating intermediate provided on a base material sheet with a heat generating composition containing iron powder, which is a magnetic powder, a water retention agent, water, etc., by containing an electrolyte, by an oxidation reaction with oxygen in the air, A manufacturing method for manufacturing a sheet-shaped heating element that generates heat is known. The present applicant has previously proposed a method for manufacturing a heat generating sheet in which the heating element is attracted from the first conveying means by the magnetic force of the magnet and transferred to the second conveying means (Patent Document 1).

JP2012-130381A

In the technique described in Patent Document 1, a cutter roll having a plurality of cutter blades and a long sheet are used as cutting means for a long sheet member containing an oxidizable magnetic metal powder that constitutes a heating element by cutting. A receiving roll having a plurality of suction ports for sucking and holding a member is used.
However, since the receiving roll has a plurality of suction ports for adsorbing and holding the long sheet member, when the oxidizable magnetic metal powder is scattered, the oxidizable magnetic metal powder enters the suction port. However, there is a possibility that problems such as contamination or clogging of the suction port may occur. Further, when the long sheet member is sucked and held by suction, a portion sucked from the suction port and a portion not sucked are generated, and the long sheet member is difficult to be uniformly attracted to the receiving roll. Therefore, if the long sheet member is cut in this state, bending moments may occur on both sides of the cutting point when there are parts that are not sucked from the suction ports on both sides of the cutting point. A phase shift may occur due to the influence. As described above, the technique described in Patent Document 1 has room for further improvement.

  Therefore, an object of the present invention is to provide a method for producing a functional sheet containing magnetic powder, which is capable of solving the above-mentioned drawbacks of the prior art.

  The present invention is a method for producing a functional sheet body, which comprises a cutting step for producing a single sheet functional sheet body by cutting a long sheet member containing magnetic powder, wherein the cutting step is a peripheral surface. A cutter roller having a cutter blade and a receiving roller arranged to face the cutter roller are used. The receiving roller is provided with a magnet, and is introduced between the cutter roller and the receiving roller in the cutting step. The long sheet member containing the magnetic powder is conveyed while being wound around the peripheral surface of the receiving roller, and cut by the cutter blade of the cutter roller to produce a single-sheet functional sheet body. The present invention provides a method for manufacturing a functional sheet body, in which the functional sheet body manufactured by cutting with the cutter blade is conveyed while being attracted to the peripheral surface of the receiving roller by the magnet.

  According to the present invention, in the cutting step of manufacturing a functional sheet body by cutting a long sheet member containing magnetic powder, during the production and transportation of the functional sheet body, contamination of the suction port by the magnetic powder or Phase shift of the functional sheet is less likely to occur, and productivity is improved.

FIG. 1 is a schematic view showing an embodiment of a manufacturing apparatus preferably used for carrying out the present invention. 2A to 2D are schematic views showing a cut state of the long sheet member in the cutting process using the manufacturing apparatus shown in FIG. FIG. 3A to FIG. 3C are schematic diagrams showing the magnetic position of the magnet of the anvil roller used in the cutting portion.

The present invention will be described below based on its preferred embodiments with reference to the drawings.
The method for producing a functional sheet body of the present invention is a method for producing a functional sheet body, which includes a cutting step of producing a sheet-shaped functional sheet body by cutting a long sheet member containing magnetic powder. FIG. 1 shows the overall configuration of a manufacturing apparatus 100 (hereinafter, also simply referred to as manufacturing apparatus 100) of a preferred embodiment used for carrying out the manufacturing method of the present embodiment. Below, the manufacturing method of the functional sheet body of this embodiment using the manufacturing apparatus 100 is demonstrated. The manufacturing method of the present embodiment includes the cutting step, and a transportation step of transporting the functional sheet body to the next step after the cutting step.

  The functional sheet body manufactured by the method for manufacturing a functional sheet body of the present embodiment is, for example, a heating element included in a heating tool. The heating element is composed of a heating element and a breathable covering sheet that covers the entire heating element. The heating element is formed by coating or spraying the heat-generating composition on one surface of the base sheet, and coating the layer of the heat-generating composition applied or dispersed (hereinafter also referred to as “heat-generating layer”) with the base sheet. The exothermic composition contains an oxidizable magnetic powder, an electrolyte, water and the like, and generates heat by utilizing an oxidation reaction of the oxidizable magnetic powder caused by contact with air.

  FIG. 1 schematically shows the manufacturing apparatus 100. Hereinafter, the manufacturing apparatus 100 will be described with reference to FIGS. 1 to 3. Further, in the following description, the sheet conveying direction for conveying a sheet is the Y direction and the width direction of the conveyed sheet is the X direction.

  As shown in FIG. 1, in the manufacturing apparatus 100, an adding section 10 for adding the heat-generating composition 2 to the belt-shaped first base material sheet 1A conveyed from the upstream side to the downstream side, and a first heat-generating composition 2 added. 1 The base material sheet 1A, the strip-shaped second base material sheet 1B is overlaid to form the long sheet member 1C containing the heat-generating composition 2, and the long sheet forming portion 20 and the long sheet member 1C are cut. A cutting unit 30 for performing a cutting process for forming a sheet-shaped heating element 1D that is a functional sheet, and a carrying unit 40 for performing a carrying process for carrying the cut heating unit 1D to the next process (for example, a heating unit forming process). Is equipped with.

In the manufacturing apparatus 100, as shown in FIG. 1, the addition unit 10 includes an application unit 11 that applies the coating liquid 3 containing the oxidizable magnetic powder, water, and the like, and a spray unit 12 that sprays the electrolyte 4. I have it. The coating unit 11 includes a die coater 13 that coats the coating liquid 3. The die coater 13 continuously applies the coating liquid 3 along the transport direction Y onto one surface of the strip-shaped first base material sheet 1A that is unrolled from a raw fabric roll and is transported in the transport direction Y. As a result, a coating layer including the coating liquid 3 containing the oxidizable magnetic powder and water is continuously formed on the one surface of the first base material sheet 1A along the transport direction Y. The coating liquid 3 continuously applied by the die coater 13 is preferably applied to the first base material sheet 1A so that part of the contained water is absorbed by the first base material sheet 1A.
Although the die coater 13 is used for the coating unit 11 in the manufacturing apparatus 100 shown in FIG. 1, roller coating, screen printing, roller gravure, knife coating, curtain coater or the like may be used instead of the die coater 13. The coating liquid 3 continuously applied by the die coater 13 is prepared in advance by a preparation device (not shown).

In the manufacturing apparatus 100, as shown in FIG. 1, the spraying section 12 is installed downstream of the coating section 11. The spraying part 12 includes a spraying device 14 for the electrolyte 4. As the spraying device 14, for example, a screw feeder, an electromagnetic feeder, an auger feeder, or the like can be used. In the manufacturing apparatus 100, the electrolyte 4 is solidified by the spraying device 14 along the transport direction Y toward the coating layer (coating liquid 3) formed on one surface of the belt-shaped first base material sheet 1A being transported. Spray continuously. The sprayed electrolyte 4 is immediately or gradually dissolved in a coating layer to form a heat generating layer 5 for a predetermined time. It suffices that the electrolyte 4 sprayed by the spraying device 14 is evenly present on the heating layer 5 by the time the heat generating element is used, and the electrolyte 4 is sprayed evenly on the coating layer when sprayed by the spraying section 12. You don't have to.
In the manufacturing apparatus 100 shown in FIG. 1, the heating layer 5 is formed by spraying the electrolyte 4 on the coating layer (coating solution 3), and the oxidation of the oxidizable magnetic substance powder starts. In order to suppress it, it is preferable to keep the subsequent production line in a non-oxidizing atmosphere.

Next, in the manufacturing apparatus 100, as shown in FIG. 1, the long sheet forming unit 20 is installed downstream of the spraying unit 12. In the long sheet forming portion 20, the heat generation layer 5 formed on one surface of the belt-shaped first base material sheet 1A is fed from a raw roll (not shown) to the surface opposite to the first base material sheet 1A. Then, the strip-shaped second base material sheets 1B conveyed in the conveyance direction Y are overlapped. By this step, the entire surface of the heat generating layer 5 is covered with the first base material sheet 1A and the second base material sheet 1B. Further, in the long sheet forming unit 20, a seal unit (not shown) is installed downstream of the roller 21. The seal portion (not shown) seals the overlapped first base material sheet 1A and second base material sheet 1B by fusion bonding.
A long member having a structure in which the heat generating layer 5 (heat generating composition 2) is sandwiched between the first base material sheet 1A and the second base material sheet 1B by the addition unit 10 and the long sheet forming unit 20 described above. The sheet member 1C is formed.

  Next, in the manufacturing apparatus 100, as shown in FIG. 1, a cutting step of manufacturing the sheet heating element 1D by cutting the elongated sheet member 1C in the width direction X downstream of the elongated sheet forming unit 20. A cutting unit 30 for performing the above is installed. The cutting unit 30 used in the cutting step has a cutter roller having a cutter blade on its peripheral surface, and a receiving roller arranged to face the cutter roller. In the manufacturing apparatus 100 shown in FIG. It has a rotary die cutter 31 as a cutter roller and an anvil roller 32 as a receiving roller.

In the present embodiment, the rotary die cutter 31 of the cutting unit 30 used in the cutting step is a substantially cylindrical roller made of metal such as aluminum alloy or steel, and has a plurality of cutters extending along the rotation axis of the roller on the circumferential surface. In the manufacturing apparatus 100 shown in FIG. 1, the rotary die cutter 31 has four cutter blades 33a, 33b, 33c, 33d extending along the rotation axis of the roller.
In addition, in the present embodiment, the plurality of cutter blades of the rotary die cutter 31 are provided on the peripheral surface of the rotary die cutter 31 at equal intervals in the circumferential direction. In the manufacturing apparatus 100 shown in FIG. The blades 33a to 33d are provided on the peripheral surface of the rotary die cutter 31 every 90 degrees along the rotation direction M. Further, in the manufacturing apparatus 100 shown in FIG. 1, the cutter blades 33a to 33d of the rotary die cutter 31 are formed so that the length in the axial direction is longer than the length in the width direction X of the long sheet member 1C. . Although the rotary die cutter 31 is provided with four blades in the present embodiment, the invention is not limited to this, and the peripheral surface of the rotary die cutter 31 is cut into five pieces so as to cut the heating elements at desired intervals (pitch). One or more blades or one to three blades may be provided.

In the manufacturing apparatus 100, as shown in FIG. 1, the rotary die cutter 31 receives the driving force from the driving means (not shown) to the rotary shaft of the roller so that the rotary die cutter 31 is rotated in the sheet conveying direction Y. It is designed to rotate in the direction. Further, the rotary die cutter 31 rotates in synchronization with the anvil roller 32. In the manufacturing apparatus 100 shown in FIG. 1, the peripheral speed of the rotary die cutter 31 is the same as the peripheral speed of the anvil roller 32. Has become. In the manufacturing apparatus 100, the rotary die cutter 31 rotates in the same direction as the sheet transport direction Y, but may rotate in the opposite direction to the sheet transport direction Y.

  In the manufacturing apparatus 100, as shown in FIG. 1, the anvil roller 32 used in the cutting step is a roller having a substantially cylindrical outer shape, and in synchronization with the rotary die cutter 31, it is in the positive direction with respect to the sheet conveyance direction Y. It is designed to rotate (rotation direction N).

  In the present embodiment using the manufacturing apparatus 100, as shown in FIG. 1, the anvil roller 32 includes a magnet 34, and in the cutting step, the oxidizable property introduced between the rotary die cutter 31 and the anvil roller 32 is used. A long sheet member 1C containing magnetic substance powder (exothermic composition 2) is conveyed while being wound around the peripheral surface of the anvil roller 32, cut by the cutter blades 33a to 33d of the rotary die cutter 31, and cut into single sheets. The heating element 1D is manufactured and cut by the cutter blades 33a to 33d, and the heating element 1D is conveyed while being attracted to the peripheral surface of the anvil roller 32 by the magnet 34.

In the cutting process of the present embodiment using the manufacturing apparatus 100, the long sheet member 1C is attracted to the peripheral surface of the anvil roller 32 by the magnet 34 included in the anvil roller 32. The sheet is conveyed in a state where it is uniformly and uniformly adsorbed on the surface (for example, in a state of being in surface contact). Therefore, when the long sheet member 1C attracted to the peripheral surface is intermittently cut by the cutter blades 33a to 33d of the rotary die cutter 31, it is possible to suppress the tensile or compressive stress caused by the cutting from being applied to the cut portion. it can. That is, it is possible to prevent the bending moment from being generated at the cut portion. Therefore, the phase shift of the heating element 1D after cutting can be prevented.
Further, in the cutting process of the present embodiment using the manufacturing apparatus 100, the long sheet member 1C is attracted to the peripheral surface of the anvil roller 32 by the magnet 34. Therefore, for example, the long sheet member 1C is wound around the anvil roller 32 by air suction. Unlike the case of attracting to the surface, the air suction hole for attracting the long sheet member 1C becomes unnecessary. Therefore, for example, since the air suction holes are not contaminated by the oxidizable magnetic substance powder or the like contained in the long sheet member 1C, cleaning of the air suction holes is not necessary and maintenance is facilitated. Furthermore, noise during suction is eliminated and power consumption can be suppressed.

In the present embodiment, the anvil roller 32 includes a plurality of blade receiving members arranged at positions corresponding to the plurality of cutter blades of the rotary die cutter 31, and in the manufacturing apparatus 100 shown in FIG. Includes four blade receiving members 35a, 35b, 35c, 35d arranged at positions corresponding to the four cutter blades 33a to 33d of the rotary die cutter 31 when rotating in synchronization with the rotary die cutter 31. ing. In the present embodiment, the rotary die cutter 31 and the anvil roller 32 rotate at the same peripheral speed, and the blade receiving members 35a to 35d of the anvil roller 32 are arranged at intervals of 90 ° along the rotation direction N. The number and arrangement interval of the blade receiving members 35a to 35d of the anvil roller 32 can be set according to the number and arrangement interval of the cutter blades 33a to 33d provided on the rotary die cutter 31.
In the cutting process of the present embodiment using the manufacturing apparatus 100, the blade receiving members 35a to 35d use a metal having a hardness higher than that of the cutter blades 33a to 33d included in the rotary die cutter 31. Damage of the anvil roller 32 when the long sheet member 1C is cut by the cutter blades 33a to 33d of the rotary die cutter 31 by using a metal having a hardness higher than that of the cutter blades 33a to 33d for the blade receiving members 35a to 35d. Etc. can be reduced. Therefore, the durability of the anvil roller 32 can be improved.
As the metal used for the blade receiving members 35a to 35d, for example, JIS B 4053 standard V10 or more is preferable, more preferably JIS B 4053 standard V20 or more, and in the present embodiment, carbide that is equivalent to JIS B 4053 standard V20. Alloy G2 (manufactured by Silver Roy Co., Ltd.) is used.

Further, in the cutting process of the present embodiment using the manufacturing apparatus 100, the interval (peripheral length) between the blade receiving members 35a to 35d adjacent to each other in the rotation direction N on the peripheral surface of the anvil roller 32 is a single sheet heating element 1D. Is longer than the length in the transport direction. For example, taking the blade receiving member 35a and the blade receiving member 35b as an example, the interval (peripheral length) between the blade receiving member 35a and the blade receiving member 35b in the rotation direction N is the length in the transport direction Y of the heating element 1D. That is all.
By setting the interval (peripheral length) between the blade receiving members 35a to 35d adjacent to each other in the rotation direction N on the peripheral surface to be equal to or longer than the length in the transport direction of the heating element 1D, the entire surface of the heating element 1D is brought into close contact with the magnet 34. be able to. Further, for example, in the transport direction Y, it is possible to provide (re-pitch) a space between the heating elements 1D and 1D.

  Further, in the present embodiment, the plurality of magnets 34 described above are arranged adjacent to the anvil roller 32 on the upstream side in the rotation direction N of each of the plurality of blade receiving members. In the manufacturing apparatus 100 shown in FIG. 1, the arc-shaped magnets 34 are arranged adjacent to each other on the upstream side of the blade receiving members 35a to 35d in the rotation direction N. In the manufacturing apparatus 100 shown in FIG. 1, the magnet 34 attached to the anvil roller 32 is preferably a permanent magnet, and the permanent magnet is preferably ferrite, neodymium, or the like.

  In the cutting process of the present embodiment using the manufacturing apparatus 100, the magnet 34 includes the first magnets 36a to 36d arranged adjacent to the upstream side of the blade receiving members 35a to 35d in the rotation direction N of the anvil roller 32, and the first magnets 36a to 36d. The first magnets 36a to 36d have second magnets 37a to 37d arranged adjacent to the upstream side in the rotation direction N of the anvil roller 32, and the magnetic forces of the first magnets 36a to 36d are the same as those of the second magnets 37a to 37d. Stronger than magnetic force.

  In the cutting process of the present embodiment using the manufacturing apparatus 100, the magnetic forces of the first magnets 36a to 36d arranged adjacent to the blade receiving members 35a to 35d are changed to the second magnets 37a arranged adjacent to the first magnets 36a to 36d. By making it stronger than the magnetic force of 37d, for example, when the long sheet member 1C is cut by the cutter blades 33a to 33d of the rotary die cutter 31, the upstream side in the rotational direction of the cutting position of the long sheet member 1C is anvil. It can be strongly attracted to the peripheral surface of the roller 32, and the positioning of the long sheet member 1C at the time of cutting can be strengthened. Therefore, it is possible to prevent a phase shift of the heating element 1D during cutting. On the other hand, by arranging the second magnets 37a to 37d having a weaker magnetic force adjacently on the downstream side of the first magnets 36a to 36d, the heat generating element 1D after cutting is smoothly transferred to a conveyor or the like in the next step. Can be handed over to.

The magnetic force of the first magnets 36a to 36d arranged adjacent to the blade receiving members 35a to 35d is preferably 50 mT (millitesla) or more, more preferably 60 mT or more, and preferably 100 mT or less, more preferably 80 mT or less, It is preferably 50 mT or more and 100 mT or less, more preferably 60 mT or more and 80 mT or less. Within the range, it is easy to ensure the cutting position of the long sheet member 1C.
The magnetic force of the second magnets 37a to 37d arranged adjacent to the first magnets 36a to 36d is preferably 10 mT or more, more preferably 20 mT or more, preferably 50 mT or less, more preferably 40 mT or less, and preferably Is 10 mT or more and 50 mT or less, and more preferably 20 mT or more and 40 mT or less. Within this range, the heating element 1D is attracted to the anvil roller 32 and reliably conveyed to the next step, and the heating element 1D is easily delivered from the anvil roller 32 to the next step.

  Further, in the cutting step of the present embodiment using the manufacturing apparatus 100, the first magnets 36a to 36d and the second magnets 37a to 37d formed in an arc shape are the first magnet 36a and the second magnet 37a as an example. To explain, the first magnet 36a has a structure in which the S pole is arranged inside and the N pole is arranged outside, and the second magnet 37a has the N pole arranged inside and the S pole arranged outside. It has a different structure. By disposing in this way, an attractive force can be generated between the first magnet 36a and the second magnet 37a, and the first magnet 36a and the second magnet 37a can be brought into close contact with each other in the circumferential direction.

  When the magnet 34 formed in an arc shape is used, the direction of the magnetic pole of the magnet 34 is, for example, as shown in FIG. May be arranged, and as shown in FIG. 3B, the N pole may be arranged inside and the S pole may be arranged outside. Further, as shown in FIG. 3C, S poles and N poles may be alternately arranged in the circumferential direction. This arrangement configuration is also applicable to the case where the first magnets 36a to 36d and the second magnets 37a to 37d in the manufacturing apparatus 100 are used.

Further, in the cutting process of the present embodiment using the manufacturing apparatus 100, the peripheral speed V1 of the anvil roller 32 is faster than the introduction speed V2 of the long sheet member 1C introduced between the rotary die cutter 31 and the anvil roller 32. Has become. By setting the peripheral speed V1 of the anvil roller 32 to be faster than the introduction speed V2 of the long sheet member 1C, the long sheet member 1C attracted to the peripheral surface of the anvil roller 32 is moved to the anvil roller in the cutting step. While being slid to the upstream side in the rotational direction of 32, the sheet is conveyed while being attracted to the peripheral surface of the anvil roller 32.
Then, in the cutting step of the present embodiment using the manufacturing apparatus 100, the long sheet member 1C is rotatably conveyed while being slid to the upstream side in the rotation direction N, so that the heating element 1D that has been previously cut and rotatively conveyed is It becomes possible to provide a space L between them.

  Specifically, in the cutting process of the present embodiment using the manufacturing apparatus 100, as shown in FIG. 2A, a long sheet member introduced between the rotary die cutter 31 and the anvil roller 32 at the introduction speed V2. First, the tip portion of 1C starts rotating together with the anvil roller 32 while being attracted to the peripheral surface of the anvil roller 32 by the first magnet 36a. At this time, the upstream side of the leading end of the long sheet member 1C is attracted to the peripheral surface of the anvil roller 32 by the second magnet 37a. However, the peripheral speed V1 of the anvil roller 32 is faster than the introduction speed V2 of the long sheet member 1C, and the rotation direction N of the anvil roller 32 is larger than the force of the first magnet 36a to attract the leading end of the long sheet member 1C. 2B, the long sheet member 1C slides on the peripheral surface of the anvil roller 32 to the upstream side in the transport direction Y after the rotation of the anvil roller 32, as shown in FIG. 2B. While being transported.

Then, in the cutting process of the present embodiment using the manufacturing apparatus 100, the anvil roller 32 further rotates, and the cutter blade 33b of the rotary die cutter 31 that rotates in synchronization with the anvil roller 32 has a blade receiving member of the corresponding anvil roller 32. When reaching the member 35b, that is, when the long sheet member 1C is cut by the cutter blade 33b, the front end portion of the long sheet member 1C is located on the upstream side by the circumferential length of the first magnet 36a. Is sliding to. At this position, the long sheet member 1C is cut by the cutter blade 33b of the rotary die cutter 31, and the cut portion becomes a single sheet heating element 1D. As shown in FIG. 2C, the cut heating element 1D is conveyed by the anvil roller 32 while being attracted by the second magnet 37a, and is separated from the next heating element 1D by a gap. L is formed.
In this way, by setting the peripheral speed V1 of the anvil roller 32 to be higher than the introduction speed V2 of the long sheet member 1C, the space L can be easily provided (re-pitch) between the heating elements 1D.

The peripheral speed V1 of the anvil roller 32, which is faster than the introduction speed V2 of the long sheet member 1C, is preferably 0.20 m / s or more, more preferably 0.50 m / s or more, and preferably 2.00 m / s or less. , More preferably 1.00 m / s or less, preferably 0.20 m / s or more and 2.00 m / s or less, and more preferably 0.50 m / s or more and 1.00 m / s or less.
The introduction speed V2 of the long sheet member 1C slower than the peripheral speed V1 of the anvil roller 32 is preferably 0.19 m / s or more, more preferably 0.49 m / s or more, and preferably 1.99 m / s or less. , More preferably 0.99 m / s or less, preferably 0.19 m / s or more and 1.99 m / s or less, and more preferably 0.49 m / s or more and 0.99 m / s or less.

Next, in the manufacturing apparatus 100, as shown in FIG. 1, the transport unit 40 that performs a transport step of transporting the cut heating element 1D to the next step (for example, a heating element forming step) downstream of the anvil roller 32. Is installed.
In the carrying process of the present embodiment using the manufacturing apparatus 100, the carrying unit 40 includes a belt conveyor 41.
In the conveying process of the present embodiment using the manufacturing apparatus 100, the belt conveyor 41 includes a plurality of rollers 42 arranged such that their rotation axes are parallel to each other, and an endless belt 43 bridged between the rollers 42. have. The endless belt 43 is configured to circulate in the direction of arrow S (clockwise) in FIG. Further, the belt conveyor 41 has a suction box 44 inside the endless belt 43, and by activating the suction box 44 in the endless belt 43, air is sucked from the outside of the circular track toward the inside. A plurality of through holes (not shown) are provided for this purpose. In the carrying process of the carrying unit 40, the attraction force of the belt conveyor 41 is stronger than the magnetic force of the magnet 34 of the anvil roller 32, and the heating element 1D that is carried while being attracted to the peripheral surface of the anvil roller 32 is carried by the belt conveyor 41. Receive and transport. In this way, since the attraction force of the belt conveyor 41 is stronger than the magnetic force of the magnet 34 of the anvil roller 32, the belt conveyor 41 can easily receive and convey the heating element 1D.
In the carrying step of the present embodiment using the manufacturing apparatus 100, as shown in FIG. 2D, the suction force of the heating element 1D by the suction box 44 causes the heating element 1D by the second magnets 37a to 37d of the anvil roller 32 to move. The heating element 1D, which is stronger than the magnetic force to be attracted and is attracted to the peripheral surface of the anvil roller 32, is received by the belt conveyor 41 and is transported. In this way, the sheet-shaped heating element 1D is conveyed toward the next step.

Next, a material for forming a member used in the heating element 1D manufactured by the manufacturing apparatus 100 will be described.
As the first and second base material sheets 1A and 1B, sheet-like materials to which the coating liquid 3 can be applied are used, and those having both properties of water absorption and smoothness of the sheet surface are particularly preferable. Examples thereof include paper mainly made of pulp fibers and obtained by a wet papermaking method, fiber sheets containing superabsorbent polymer and pulp fibers, and non-woven fabric mainly made of synthetic fibers. The basis weight of the first and second base material sheets 1A and 1B is not particularly limited, but is preferably 30 g / m ² or more, more preferably 80 g / m ² or more, and preferably 200 g / m ² or less, more preferably Is 120 g / m ² or less, more specifically 30 g / m ² or more and 200 g / m ² or less, and further preferably 80 g / m ² or more and 120 g / m ² or less.

The coating liquid 3 applied by the application unit 11 preferably contains an oxidizable magnetic substance powder, a carbon component, a thickener, and water.
Examples of the oxidizable magnetic substance powder contained in the coating liquid 3 include iron, aluminum, zinc, manganese, magnesium, calcium and the like, and one of these may be used alone or in combination of two or more. You can Among these magnetic powders, iron, which is an oxidizable magnetic powder, is preferably used in the present invention as a heating element. The particle diameter of the particles of the oxidizable magnetic substance powder is preferably 0.1 μm or more, more preferably 5 μm or more, and preferably 300 μm or less, more preferably 100 μm or less, particularly preferably 50 μm or less, and more specifically The thickness is preferably 0.1 μm or more and 300 μm or less, more preferably 5 μm or more and 100 μm or less, and particularly preferably 5 μm or more and 50 μm or less. The particle size of the oxidizable magnetic powder was measured by a wet method using a laser diffraction particle size distribution analyzer (SALD-300V, manufactured by Shimadzu Corporation), and the median size was defined as the particle size.

  As the carbon component contained in the coating liquid 3, one having a function capable of promoting the oxidation reaction between oxygen in the air and the oxidizable magnetic substance powder in the heating element 1D is used. A substance having not only a function as a water retention agent but also an function as an oxygen retention agent and an oxygen supply agent to the oxidizable magnetic substance powder is preferably used. Examples of the carbon component include activated carbon (coconut shell charcoal, charcoal powder, calendar blue coal, peat, lignite, etc.), carbon black, acetylene black, graphite and the like, and one of these may be used alone or two or more may be used. It can be mixed and used. These carbon components are usually powder. The particle size of the carbon component particles is preferably 0.1 μm or more, more preferably 1 μm or more, and preferably 100 μm or less, more preferably 50 μm or less, particularly preferably 30 μm or less, and more specifically, 0 .1 μm or more and 100 μm or less, more preferably 1 μm or more and 50 μm or less, and particularly preferably 1 μm or more and 30 μm or less. The particle diameter of the carbon component particles was measured by a wet method using a laser diffraction particle size distribution measuring device (SALD-300V, manufactured by Shimadzu Corporation), and the median diameter was defined as the particle diameter.

  The thickener contained in the coating liquid 3 is mainly used for suppressing the sedimentation of particles of the oxidizable magnetic substance powder and imparting an appropriate fluidity to the coating liquid 3. , Starch type, poly (meth) acrylic acid (salt, ester) type, syrup type, seaweed, plant mucilage, microbial mucilage, protein type, polysaccharide type, organic type, inorganic type, synthetic type, etc. Examples thereof include molecular molding aids, and these can be used alone or in combination of two or more. Among these thickeners, polysaccharide-based ones, especially xanthan gum, are preferably used in the present invention.

The coating liquid 3 preferably contains 25 parts by mass or more, and particularly 35 parts by mass or more of water with respect to 100 parts by mass of the oxidizable magnetic substance powder. Further, the coating liquid 3 preferably contains 85 parts by mass or less, and particularly 75 parts by mass or less of water with respect to 100 parts by mass of the oxidizable magnetic substance powder. For example, the coating liquid 3 preferably contains 25 parts by mass or more and 85 parts by mass or less, particularly 35 parts by mass or more and 75 parts by mass or less of water with respect to 100 parts by mass of the oxidizable magnetic substance powder. Further, the proportion of water contained in the coating liquid 3 is preferably 18% by mass, particularly 23% by mass or more based on the total mass of the coating liquid 3. The proportion of water contained in the coating liquid 3 is preferably 48% by mass or less, particularly 43% by mass or less, based on the total mass of the coating liquid 3. For example, the proportion of water contained in the coating liquid 3 is preferably 18% by mass or more and 48% by mass or less, and particularly preferably 23% by mass or more and 43% by mass or less.
The viscosity of the coating liquid 3 at 23 ° C. and 50 RH is preferably 500 mPa · s or more, particularly preferably 1000 mPa · s or more, preferably 30,000 mPa · s or less, particularly preferably 15,000 mPa · s or less, and particularly preferably 10,000 mPa · s. It is preferably s or less and, for example, 500 to 30000 mPa · s, particularly 1000 to 15000 mPa · s, and particularly 1000 to 10000 mPa · s. A No. 4 rotor of B type viscometer was used for measuring the viscous viscosity. The measurement was performed by rotating the rotor at 6 rpm.

  As described above, according to the manufacturing method for manufacturing the heating element 1D of the present embodiment, the long sheet member 1C is attracted to the peripheral surface of the anvil roller 32 by the magnet 34 included in the anvil roller 32. The sheet member 1C is conveyed in a state where the sheet member 1C is evenly and uniformly adsorbed on the peripheral surface of the anvil roller 32. Therefore, when the long sheet member 1C attracted to the peripheral surface is cut by the cutter blades 33a to 33d of the rotary die cutter 31, it is possible to suppress the tensile or compressive stress caused by the cutting from acting on the cut portion. Therefore, the phase shift of the heating element 1D after cutting can be suppressed, and the continuous production of the heating element 1D becomes possible.

  Further, according to the manufacturing method for manufacturing the heating element 1D of the present embodiment, since the long sheet member 1C is attracted to the peripheral surface of the anvil roller 32 by the magnet 34, for example, the long sheet member 1C is sucked by air suction. Unlike the case where the long sheet member 1C is attracted to the peripheral surface, the air suction hole for attracting the long sheet member 1C is not necessary. Therefore, for example, since the air suction holes are not contaminated by the oxidizable magnetic substance powder or the like contained in the long sheet member 1C, cleaning of the air suction holes is not necessary and maintenance is facilitated. Furthermore, noise during suction is eliminated and power consumption can be suppressed.

  Thus, according to the manufacturing method for manufacturing the heating element 1D of the present embodiment, in the cutting step of manufacturing the heating element 1D by cutting the long sheet member 1C containing the oxidizable magnetic powder, During the production and transportation of 1D, the contamination of the suction port due to the oxidizable magnetic substance powder and the phase shift of the heating element hardly occur, and the productivity can be improved.

  Although the present invention has been described above based on its preferred embodiments, the present invention is not limited to the above embodiments and can be modified as appropriate.

  For example, in the above-described embodiment, the heating element included in the heating tool is manufactured, but the method for manufacturing a functional sheet of the present invention has a function of containing magnetic powder other than the heating element and the heating tool including the heating element. It can be used for a method of manufacturing a flexible sheet body. For example, examples of the functional sheet body include a conductive film and a battery sheet.

  Further, in the above embodiment, the permanent magnet is used as the magnet 34 included in the anvil roller 32 of the manufacturing apparatus 100, but an electromagnet may be used instead of the permanent magnet. The use of the electromagnet makes it easy to control the magnetic force. For example, it becomes easy to control the magnetic force when the heating element 1D is transferred from the anvil roller 32 to the transport unit 40.

  Further, in the above embodiment, a belt conveyor is used as the conveyor 40 of the manufacturing apparatus 100, and the heating element 1D that is conveyed by the suction force of the heating element 1D by the suction box 44 is received and conveyed by the belt conveyor 41. A magnet may be arranged inside the belt 43, and the heating element 1D that is conveyed by the magnetic force of the magnet may be received and conveyed by the belt conveyor 41, and may be conveyed by both the suction force of the suction box 44 and the magnetic force of the magnet. The heating element 1D may be received by the belt conveyor 41 and conveyed.

  Further, in the above-described embodiment, the heat generating element is used as the functional sheet body, and the oxidizable magnetic body powder contained in the heat generating body is used as the magnetic body powder. It may be a functional sheet containing a magnetic substance powder other than the magnetic substance powder.

1A 1st base material sheet 1B 2nd base material sheet 1C Long sheet member 1D Functional sheet body (heating element)
2 Exothermic composition 5 Exothermic layer 30 Cutting part 31 Rotary die cutter 32 Anvil roller 33a-33d Cutter blade 34 Magnet 35a-35d Blade receiving member 36a-36d 1st magnet 37a-37d 2nd magnet 40 Conveying part 41 Belt conveyor 43 Endless Belt 44 Suction box 100 Manufacturing equipment

Claims (5)

A method for producing a functional sheet body having a cutting step of producing a single-piece functional sheet body by cutting a long sheet member containing a magnetic powder,
The cutting step uses a cutter roller having a cutter blade on the peripheral surface and a receiving roller arranged to face the cutter roller,
The receiving roller includes a magnet,
In the cutting step, the long sheet member containing the magnetic powder introduced between the cutter roller and the receiving roller is conveyed while being wound around the peripheral surface of the receiving roller, The functional sheet body manufactured by cutting with the cutter blade is manufactured by cutting with the cutter blade, and the functional sheet body manufactured by cutting with the cutter blade is conveyed while being attracted to the peripheral surface of the receiving roller by the magnet. A method for manufacturing a functional sheet body. The peripheral speed of the receiving roller is faster than the introduction speed of the long sheet member introduced between the cutter roller and the receiving roller,
In the cutting step, the long sheet member wound around the peripheral surface of the receiving roller is conveyed while being slid around the peripheral surface of the receiving roller while sliding to the upstream side in the rotation direction of the receiving roller. The method for manufacturing the functional sheet body according to claim 1. The receiving roller includes a blade receiving member arranged at a position corresponding to the cutter blade of the cutter roller,
The magnet of the receiving roller is adjacent to a first magnet disposed adjacent to the upstream side of the blade receiving member in the rotational direction of the receiving roller, and adjacent to the upstream side of the first magnet in the rotational direction of the receiving roller. And a second magnet arranged as
The method for manufacturing a functional sheet body according to claim 1, wherein the magnetic force of the first magnet is stronger than the magnetic force of the second magnet.   The method for manufacturing a functional sheet body according to claim 3, wherein the interval between the blade receiving members that are adjacent to each other in the rotation direction on the peripheral surface of the receiving roller is equal to or more than the length in the transport direction of the functional sheet body. In a step after the cutting step, there is a carrying step for carrying the functional sheet body to the next step,
The transfer step uses a belt conveyor,
The attraction force of the belt conveyor is stronger than the magnetic force of the magnet of the receiving roller,
5. In the carrying step, the functional sheet member being carried in a state of being attracted to the peripheral surface of the receiving roller is received by the belt conveyor and carried to the next step. A method for producing the described functional sheet body.

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