JP7283350B2 - NONWOVEN FABRIC MANUFACTURING APPARATUS AND NONWOVEN FABRIC MAKING METHOD - Google Patents

Description

TECHNICAL FIELD The present invention relates to a nonwoven fabric manufacturing apparatus and a nonwoven fabric manufacturing method for collecting a bundle of fibrous filaments on a conveying surface of a conveyor to fabricate a sheet-like nonwoven fabric.

Nonwoven fabrics are produced by spraying fibrous filaments from a spinning device that melts and ejects thermoplastic resin onto the conveying surface of a conveyor and collecting them in the form of a sheet (see, for example, Patent Document 1). For this type of nonwoven fabric, for example, as described in Patent Document 2, a multi-layered nonwoven fabric having different functions for each layer can be produced by arranging two spinning devices in parallel in the moving direction of the conveying surface of the conveyor. is disclosed.

JP 2012-144840 A JP 2016-141929 A

However, in a nonwoven fabric produced in multiple layers in this way, since filaments from different spinning devices are sprayed onto the conveying surface on the conveyor and collected layer by layer, problems may arise in bonding the layers. . For example, it is difficult to obtain a sufficient bonding strength, and there is a possibility that peeling or the like occurs during the manufacturing process.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a nonwoven fabric production apparatus and a nonwoven fabric production method capable of producing a multi-layered nonwoven fabric with high quality.

One aspect of the invention of a nonwoven fabric manufacturing apparatus for solving the above problems is a fiber jetting device for jetting a bundle of fibrous filaments jetted out after melting a thermoplastic resin, and the filaments jetted from the fiber jetting device. a sheet conveying device that collects a bundle of filaments on a conveying surface to form a sheet-shaped nonwoven fabric and conveys it in the conveying direction, wherein the fiber spraying device is configured so that the filament is centered on the discharge direction. adjusting means for adjusting the rotational diameter of the filament when the filament is sprayed onto the conveying surface of the sheet conveying device while rotating around the sheet conveying device, and are arranged at a plurality of locations on the conveying surface in the conveying direction. It is characterized by

One aspect of the nonwoven fabric manufacturing method that solves the above problems is to bundle fibrous filaments that are melted and discharged from a thermoplastic resin and eject them toward a conveying surface to collect them, thereby forming a sheet-shaped nonwoven fabric. In a method for producing a nonwoven fabric that is conveyed in a conveying direction, when the filaments are sprayed and collected at a plurality of locations on the conveying surface in the conveying direction, the filaments are entangled with the upstream side by varying the rotation diameter of the filaments. It is characterized in that it is made into a non-woven fabric.

Thus, according to one aspect of the present invention, each sheet-like layer can be stacked with a different diameter of rotation of the filaments, and the filaments in the layers are entangled with each other to produce a multi-layered nonwoven fabric. be able to.

Therefore, it is possible to provide a nonwoven fabric production apparatus and a nonwoven fabric production method capable of producing a multi-layered nonwoven fabric with high quality.

FIG. 1 is a diagram showing a nonwoven fabric manufacturing apparatus for executing a nonwoven fabric manufacturing method according to a first embodiment, and is a system conceptual diagram showing a schematic overall configuration thereof. FIG. 2 is an explanatory diagram for explaining the state in which the ejected filament descends. FIG. 3 is an explanatory diagram for explaining the adjustment of the circulating rotation diameter of the descending filament. FIG. 4 is a configuration diagram showing a first alternative embodiment of the filament rotation diameter adjusting means. FIG. 5 is a configuration diagram showing a second alternative mode of the filament rotation diameter adjusting means. FIG. 6 is an explanatory diagram for explaining a third alternative mode of the filament winding diameter adjusting means. FIG. 7 is a diagram showing a nonwoven fabric production apparatus for executing the nonwoven fabric production method according to the second embodiment, and is a system conceptual diagram showing a schematic overall configuration thereof.

A detailed description will be given below with reference to the drawings. FIG. 1 is a diagram showing a nonwoven fabric manufacturing apparatus for executing a nonwoven fabric manufacturing method according to a first embodiment of the present invention.

In FIG. 1, the nonwoven fabric production apparatus 1 includes three sets of jetting devices (fiber jetting devices) 10, each jetting device 10 (10A, 10B, 10C) comprising a spinning device 20, a cold air device 30 and an injector. 40 is built. In this nonwoven fabric manufacturing apparatus 1, together with an ejection device 10, a collecting conveyor (sheet conveying device) 50, an embossing device 60, and a winder 70 are arranged in series so that various processes can be executed. The ejection devices 10A, 10B, and 10C are arranged in series in the conveying direction with respect to the conveying surface above the collection conveyor 50. As shown in FIG. This nonwoven fabric production apparatus 1 is constructed to continuously produce a nonwoven fabric C whose width direction is the direction toward the paper surface of FIG. A nonwoven fabric C is produced by a so-called spunbond manufacturing method in which fibers are appropriately bonded by processing.

The spinning device 20 comprises an extruder 21 and a spinneret 23 . The extruder 21 melts the raw material resins R (R1, R2, R3) supplied to the hopper 22, and sends out a predetermined flow rate of melted material to the spinneret 23 by rotating the spiral rotor 21r. The spinneret 23 has a plurality of composite spinning nozzles (not shown) configured to discharge while forming the desired fibrous structure, and the melt from the extruder 21 into a plurality of filaments (fibers) f. A bundle (hereinafter referred to as "filament assembly") F is spun out (discharged) in the direction of gravity.

Here, the raw material resin R may be formed into multiple layers by stacking sheet-like filaments of the same materials R1, R2, and R3 without changing the type for each of the ejection devices 10A, 10B, and 10C. Sheet-like filaments of different materials R1, R2, and R3 may be layered to form multiple layers by changing the type every 10C. For example, as the raw material resin R, a thermoplastic resin is the main component, and the same or different polyolefin resins such as polypropylene (PP) and polyethylene (PE) can be used. Additives such as various stabilizers such as known heat stabilizers and weather stabilizers, antistatic agents, slip agents, antiblocking agents, antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils, waxes, etc. You may make it contain.

The cooling air device 30 includes a pair of open-type air blowers 31 and 32 arranged at opposing positions. The cooling air device 30 cools the filament assembly F discharged from the spinning device 20 and passing downward from above by blowing cooling air Ac from each of the blowers 31 and 32 . Here, the cooling air device 30 is installed by installing a large type so that one blower 31 can be used as a main, and a small type is selected and installed so that the other blower 32 facing each other can be used as a sub. .

The injector 40 blows downward high-pressure air as a driving fluid to the filament assembly F that descends so as to pass through the body 41 in the spinning direction from above to below, so that the inlet side of the body 41 is exposed to a low pressure. It has a structure that generates a region. The injector 40 pulls the descending filament assembly F into the low-pressure area on the entrance side of the body 41, and also pulls it downward with high-pressure air in the body 41, so that The filament assembly F descending from above in the spinning direction is drawn.

The collection conveyor 50 is constructed by including a main conveyor 51 , sub-conveyors 52 and 53 , and a suction box (suction means) 54 . The main conveyor 51 is installed so that a net-like collection belt 151 wider than the width of the filament assembly F and permeable to the front and back is wound around a group of rollers 151r and driven to rotate. In the sub-conveyors 52 and 53, mesh collection belts 152 and 153, which are wider than the width of the filament assembly F and can be ventilated on the front and back sides, are wound around rollers 152r and 153r, respectively, and are oriented in opposite directions. It is installed so that it can be driven around.

The collection belt 151 has a length such that the upper surface 151a is reliably positioned at the ejection point below the ejection devices 10A, 10B, and 10C, and is wound around a group of rollers 151r. By receiving and transporting the incoming filament assembly Fa, it is collected in the form of cloth (sheet). That is, the collection belt 151 is driven to rotate from the upstream end (head) toward the downstream end (tail) in the direction of circulating movement (transportation direction) of the upper surface 151a, so that the sheet-like filament assembly is collected. It has a sufficient area to collect Fa and functions as a collection surface and a transport surface.

The collecting belt 152 is wound around a group of rollers 152r with its upper surface 152a positioned at a jetting position below the jetting device 10B, which is positioned in the middle of the circulating movement direction of the upper surface 151a of the collecting belt 151. The filament assembly Fb that is pulled down by is received and transported to collect it in the form of a sheet. Further, the collection belt 153 has the upper surface 153a positioned at the jetting position below the jetting device 10C positioned at the downstream end (the rearmost end) of the upper surface 151a of the collection belt 151 in the direction of revolving movement, and the rollers 153r group. , and receives and transports the filament assembly Fc pulled down by the injector 40 to collect it in the form of a sheet.

These collection belts 152 and 153 are installed at positions deviated downstream from below the ejection device 10A located at the upstream end (head) of the upper surface 151a of the collection belt 151 in the direction of revolving movement. By being positioned between the upper surface 151a and the ejection devices 10B and 10C and driven to rotate in the reverse direction, the respective upper surfaces 152a and 153a serve as collecting surfaces and conveying surfaces for collecting the sheet-like filament aggregates Fb and Fc. function as These collection belts 152 and 153 are rotated so as to sandwich the sheet-like filament aggregates Fb and Fc between the collection belt 151 and the lower portion thereof facing the upper surface (upper portion) 151a, thereby moving the collection belt 151 toward the downstream side. Functions to assist transport.

The suction box 54 is accommodated in the collection belt 151 of the main conveyor 51 and divided into suction chambers 154a, 154a-2, 154b, 154b-2, 154c, and 154c-2 functioning as vacuum chambers. These suction chambers 154a to 154c-2 are provided with suction ports (not shown) so as to suck the upper portion, and are connected to individually drivable suction fans 155a to 155c-2 so as to be capable of suction.

The suction chambers 154a, 154b, 154c are installed below the injectors 40 of the ejection devices 10A, 10B, 10C, respectively. , 154b and 154c.

The suction chamber 154a is installed so as to be positioned directly below the collection belt 151 of the main conveyor 51 below the injector 40 of the ejection device 10A. Suction upwards from directly below.

The suction chamber 154a-2 is adjacent to the downstream side of the suction chamber 154a and, as will be described later, is positioned directly below the collection belt 151 of the main conveyor 51 between the suction chamber 154b positioned below the ejection device 10B. When the suction fan 155a-2 is driven to reduce the pressure, the collection belt 151 is sucked from directly below it.

As a result, the filament assembly Fa spun by the ejection device 10A is sucked by the suction chamber 154a below the collection belt 151 of the main conveyor 51 so as to be collected on the upper surface 151a. For this reason, the filament assembly Fa is collected and held in a sheet form on the upper surface 151a as the collection belt 151 revolves in the longitudinal direction, and is transported. After that, the filament assembly Fa is transferred from the suction chamber 154a to the adjacent suction chamber 154a-2 as the collection belt 151 rotates in the longitudinal direction, and is sucked so as to maintain the sheet shape. held and transported.

The suction chamber 154b is installed so as to be positioned directly below the collection belt 151 of the main conveyor 51 below the injector 40 of the ejection device 10B. , the upper part of the collection belt 152 of the sub-conveyor 52 is sucked from directly below.

The suction chamber 154b-2 is adjacent to the downstream side of the suction chamber 154b and, as will be described later, is positioned directly below the collection belt 151 of the main conveyor 51 between the suction chamber 154c positioned below the ejection device 10C. When the suction fan 155b-2 is driven to reduce the pressure, the collection belt 151 is sucked from directly below it.

As a result, the filament assembly Fa spun by the jetting device 10A is transferred to the upper surface 151a by the suction chambers 154b and 154b-2 below the collection belt 151 of the main conveyor 51, following the suction chambers 154a and 154a-2. It is sucked and held in the form of a sheet and transferred.

Also, the filament assembly Fb spun by the ejection device 10B is collected on the upper surface 152a of the collection belt 152 of the sub-conveyor 52 on the upper surface 151a by the suction chamber 154b below the collection belt 151 of the main conveyor 51. is attracted to Therefore, the filament assembly Fb is collected and held in a sheet form on the upper surface 152a as the collection belt 152 revolves in the longitudinal direction, and is transported.

By the way, since the collection belt 152 of the sub-conveyor 52 rotates in the opposite direction to the collection belt 151 of the main conveyor 51, the upper surface 152a of the collection belt 152 moves in the opposite direction and then is turned upside down. Then, they face the upper surface 151a of the collection belt 151 of the main conveyor 51 and move in the same direction. For this reason, the filament assembly Fb spun by the ejection device 10B is collected and held in a sheet form on the upper surface 152a of the collection belt 152 of the sub-conveyor 52, and after being transported, is transferred to the collection belt 151 of the main conveyor 51. The sheet-like filament assembly Fa on the upper surface 151a is overlapped with the sheet-like filament assembly Fa, and the sheet-like filament assembly Fa is sucked and held by the suction chamber 154b below the collection belt 151 of the main conveyor 51 and transferred.

As a result, the filament assembly Fab (Fa, Fb) collected and held in a sheet form and stacked under the jetting device 10B moves around the suction chamber 154b as the collecting belt 151 moves in the longitudinal direction. 154b-2, and transferred while being sucked and held so as to maintain the sheet shape.

The suction chamber 154c is installed so as to be positioned directly below the collection belt 151 of the main conveyor 51 below the injector 40 of the ejection device 10C. The upper part of the collecting belt 153 of the sub-conveyor 53 is sucked from directly under the .

The suction chamber 154c-2 is adjacent to the downstream side of the suction chamber 154c, and is installed so as to be positioned just below the end of the collection belt 151 of the main conveyor 51, as will be described later. 155c-2 is driven and decompressed, thereby sucking from directly below the collection belt 151 to above.

As a result, the filament aggregates Fab spun by the ejection devices 10A and 10B are transferred to the upper surface 151a by the suction chambers 154c and 154c-2 below the collection belt 151 of the main conveyor 51, following the suction chambers 154a to 154b-2. It is sucked and held and transported in the form of an overlaid sheet.

Also, the filament assembly Fc spun by the ejection device 10C is collected on the upper surface 153a of the collection belt 153 of the sub-conveyor 53 on the upper surface 151a by the suction chamber 154c below the collection belt 151 of the main conveyor 51. is attracted to Therefore, the filament assembly Fc is collected and held in a sheet form on the upper surface 153a as the collection belt 153 revolves in the longitudinal direction, and is transported.

By the way, since the collecting belt 153 of the sub-conveyor 53 also rotates in the opposite direction to the collecting belt 151 of the main conveyor 51, the upper surface 153a of the collecting belt 153 moves in the opposite direction and then turns upside down. Then, they face the upper surface 151a of the collection belt 151 of the main conveyor 51 and move in the same direction. Therefore, the filament assembly Fc spun by the ejection device 10C is collected and held in a sheet form on the upper surface 153a of the collecting belt 153 of the sub-conveyor 53, and then transferred to the collecting belt 151 of the main conveyor 51. The sheet-like filament assembly Fab on the upper surface 151a is overlapped with the sheet-like filament assembly Fab, and the suction chamber 154c under the collection belt 151 of the main conveyor 51 sucks and holds the sheet-like filament assembly Fab and transfers it.

Therefore, the filament assembly Fabc (Fa, Fb, Fc) collected and held in a sheet form and stacked under the ejection device 10C is sucked as the collection belt 151 rotates in the longitudinal direction. The sheet is transferred from the chamber 154c to the adjacent suction chamber 154c-2 and is sucked and held so as to maintain the sheet shape.

In short, the collection conveyor 50 is configured to form a sheet of a predetermined thickness by the suction box 54 on the upper surfaces 151a to 153a of the collection belts 151 to 153, and the filament aggregates Fa, Fb, and Fc spun by the ejection devices 10A, 10B, and 10C. The filament assembly Fabc (nonwoven fabric C) before embossing is made into a filament assembly Fabc (nonwoven fabric C) before embossing by collecting the filaments while holding them under vacuum, and then transferring them downstream to the sushi embossing device 60 .

The embossing device 60 has a pair of embossing rolls 61 and 62, and the cylindrical outer peripheral surfaces 61a and 62a thereof are brought into pressure contact with each other to rotate relative to each other. This embossing device 60 has a smooth cylindrical outer peripheral surface 61a of a lower embossing roll 61 and an embossing protrusion (not shown) arranged regularly or irregularly on a cylindrical outer peripheral surface 62a of an upper embossing roll 62 as desired. Press with a pressure contact force.

As a result, the embossing device 60 feeds out the filament assembly Fabc sandwiched between the embossing rolls 61 and 62 in the relative rotation direction, and entangles the filaments f at a plurality of embossing locations corresponding to the embossing projection formation positions. The nonwoven fabric C is processed into a nonwoven fabric C that maintains its sheet-like shape by applying an embossing process that presses and joins together. The embossing projections formed on the cylindrical outer peripheral surface 62a of the embossing roll 62 may be formed on the cylindrical outer peripheral surface 61a side of the embossing roll 61, or may be formed on both of these cylindrical outer peripheral surfaces 61a and 62a. Furthermore, it is not limited to a convex shape, and may be formed in a concave shape and, for example, a continuous rib shape may be pressed against the mating cylindrical surface to be pressure-bonded.

The winder 70 receives the nonwoven fabric C in which the filaments f of the filament assembly Fabc are entangled and joined by the embossing device 60 while adjusting the tension so as not to loosen the nonwoven fabric C, and continuously winds the nonwoven fabric C into a desired winding without wrinkles. Wind up into a roll with firmness.

As a result, the winder 70 can prepare a desired length of the nonwoven fabric C in which the filament assembly Fabc is formed into a sheet and wound into a roll so that it can be supplied to the next processing step or the like.

In the collection conveyor 50 of the present embodiment, as described above, the suction chambers 154a to 154c-2 of the suction box 54 installed under the collection belt 151 of the main conveyor 51 are the injectors of the ejection devices 10A to 10C. The suction fans 155a to 155c-2 connected to each of the suction chambers 154a to 154c-2 are divided and installed so as to correspond to every 40 units, and the suction fans 155a to 155c-2 connected to the suction chambers 154a to 154c-2 are divided and installed according to the required suction pressure. It is set to suck at the corresponding wind speed (air volume). Here, the partition range and suction pressure of the suction chambers 154a to 154c-2 may be appropriately set.

Specifically, the suction chamber 154a captures the filament assembly Fa pulled down from the outlet of the injector 40 of the ejection device 10A directly above the collection belt 151 of the main conveyor 51 without the intervention of a sub-conveyor. It is sucked from below the collecting belt 151 to collect and hold it in the form of a sheet.

The suction chamber 154a is partitioned so that a suction pressure Pa capable of stably holding the descending filament assembly Fa is generated under the conveying surface of the collecting belt 151 in a narrow range about the spraying region in the transport direction. The inside of the partitioned area is sucked by the suction fan 155a and the pressure is reduced to a negative pressure.

The suction chambers 154b and 154c suck the filament aggregates Fb and Fc pulled down from the exits of the injectors 40 of the ejection devices 10B and 10C directly above the collection belts 152 and 153 of the sub-conveyors 52 and 53, respectively. The particles are sucked from below the collecting belt 151 via 52 and 53 to be collected and held in the form of a sheet. These sub-conveyors 52 and 53 sandwich the sheet-like filament aggregates Fb and Fc collected and held on the collection belts 152 and 153, respectively, between them and the collection belt 151 at the bottom to transport the filament assembly Fab. , Fabc downstream.

These suction chambers 154b and 154c are equipped with suction fans 155b and 155c so that suction pressures Pb and Pc capable of stably holding the descending filament aggregates Fb and Fc are generated below the conveying surfaces of the collecting belts 152 and 153. It is driven to a negative pressure. Similar to the suction chamber 154a, these suction chambers 154b and 154c are designed so that the desired suction pressures Pb and Pc are generated in a narrow division range equivalent to the jetting region of the descending filament aggregates Fb and Fc in the transfer direction. , and suction fans 155b and 155c to create a negative pressure. At the same time, these suction chambers 154b and 154c suck the collection belts 152 and 153 of the sub-conveyors 52 and 53 through the filament aggregates Fab and Fabc on the collection belt 151, respectively. For this reason, these suction chambers 154b and 154c adjust the suction range in the transfer direction under the collection belt 151 so that the optimum suction pressures Pb and Pc are generated on the collection belts 152 and 153, thereby increasing the suction volume. It may be increased or decreased, and the collection belts 152 and 153 may also be partitioned so that the suction range can be adjusted.

As a result, the suction chambers 154b and 154c continue to suck and hold the filament aggregates Fab and Fabc increased from the sheet-like filament aggregate Fa via the collection belt 151 of the main conveyor 51, similarly to the suction chamber 154a. can do.

The suction chambers 154a-2, 154b-2 and 154c-2 respectively continuously feed the sheet-like filament aggregates Fa, Fab and Fabc on the collecting belt 151 of the main conveyor 51 downstream of the suction chambers 154a, 154b and 154c. Aspirate and hold.

These suction chambers 154a-2, 154b-2 and 154c-2 have suction pressures Pa-2 and Pb-2 for continuously sucking and holding the sheet-like filament aggregates Fa, Fab and Fabc on the collection belt 151, respectively. , Pc-2 is driven to create a negative pressure. The suction chambers 154a-2 and 154b-2 are interposed between the suction chambers 154a, 154b, and 154c and are continuous so as to suck without gaps. It is installed to suck a wider compartment range so as to connect the In addition, the suction chamber 154c-2 is installed so as to suck a shorter division range because it only transfers the sheet-like filament assembly Fabc received from the suction chamber 154c to the embossing device 60 adjacent downstream. ing.

As a result, the suction chambers 154a-2, 154b-2, and 154c-2 respectively suck the sheet-like filament aggregates Fa, Fab, and Fabc located on the upper surface 151a via the collecting belt 151 of the main conveyor 51. Suction and hold can be continuously applied to chambers 154a, 154b, 154c. At this time, since the sheet-like filament aggregates Fa and Fab on the collection belt 151 of the main conveyor 51 are sucked and held by the suction chambers 154a-2 and 154b-2, respectively, the sub-conveyors 52 and Fab do not float up. It is sandwiched between collection belts 152 and 153 of 53. The sheet-like filament assemblies Fa and Fab are collected and held by the collection belts 152 and 153, and the sheet-like filament assemblies Fb and Fc which are turned upside down are superimposed to obtain the sheet-like filament assemblies Fab, It is made Fabc and transferred downstream while being sucked and held. Here, the collection conveyor 50 eliminates the static electricity generated when the static eliminator De is installed in front of the sub-conveyors 53, 53, and the sub-conveyors 53, 53 are collected. The sheet-like filament aggregates Fa and Fab are prevented from thickening due to electrostatic force before the conveyors 52 and 53 and strongly interfering with the collecting conveyors 52 and 53, thereby preventing deterioration in quality. It's becoming

As described above, the collection conveyor 50 of this embodiment applies a sufficient suction pressure P to the collection belt 151 of the main conveyor 51 to collect and hold the sheet-like filament assembly F by the suction box. The individual suction fans 155a-155c-2 are set to draw at the required wind speeds so as to generate for each of the 54 suction chambers 154a-154c-2. The relative relationship (strength) of the suction pressure P on the collecting surface (conveying surface) of the filament assembly F in each of the suction chambers 154a to 154c-2, which will be described below, depends on the connection points of the suction fans 155a to 155c-2. A description will be given by calculating a wind speed value corresponding to the space to the collection surface and using it as a substitute.

For example, the suction box 54 is configured such that the suction pressures Pa, Pb, and Pc of the suction chambers 154a, 154b, and 154c located at the locations where the filament aggregates F are jetted by the jetting devices 10A, 10B, and 10C on the collecting conveyor 50 are respectively downstream. are adjusted to be greater than the suction pressures Pa-2, Pb-2 and Pc-2 of the suction chambers 154a-2, 154b-2 and 154c-2 located on the side. In addition, the suction pressure Ps (Pa, Pa-2) of the suction chambers 154a, 154a-2 on the leading side in the transfer direction of the filament aggregate F, and the suction pressure Pm ( Pb, Pb-2) and the suction pressure Pe (Pc, Pc-2) of the suction chambers 154c, 154c-2 on the rearmost side. The positional suction pressure Pm can be adjusted to be lower than the leading side suction pressure Ps and the rearmost side suction pressure Pe (Ps>Pm and Pe>Pm). The respective suction pressures Pa, Pb, and Pc are set so that the suction chambers 154a, 154b, and 154c are not excessively decompressed and the smooth relative movement of the collection belt 151 is not hindered. It is adjusted according to the weight of F.

Specifically, the suction chamber 154a is wound into a roll by the winder 70, for example, as the suction pressure Pa in the collection belt 151 of the main conveyor 51 that collects and holds the filament assembly Fa spun by the ejection device 10A in a sheet form. The wind speed Pa is set to 7.5 when manufacturing the nonwoven fabric C with a weight of 65 g/m ² or 15 g to 19 g/m ² of the semi-finished product. The suction pressure (wind speed) Pa is the point where the filament assembly Fa is sucked to start collecting and holding it in a sheet form. It is set to a strong value so that

The suction chamber 154a-2 is connected to the suction chamber 154a ^, and similarly, as the suction pressure Pa- ² , for example, the air speed Pa- 2 is set to 3.8. Here, the suction pressure (wind speed) Pa-2 may be such that the sheet-like shape is maintained by suction regardless of the basis weight (weighing weight) of the filament assembly Fa, similarly to the suction pressure Pa. , is sandwiched between the collecting belts 151 and 152 of the main conveyor 51 and the sub-conveyor 52 as it is, so the suction pressure Pa is suppressed to about half of the suction pressure Pa.

In the suction chamber 154b, the suction pressure Pb is set to, for example, a wind speed Pb of 6.0 when manufacturing a nonwoven fabric C with a basis weight of 65 g/m ² , and a nonwoven fabric C with a basis weight of 15 g to 19 g/m ² is set. The wind speed Pb is set to 5.8 when manufacturing. Similar to the suction pressure Pa, the suction pressure (wind speed) Pb is set to be high regardless of the basis weight because the filament assembly Fb is collected and formed into a sheet on the collection belt 152 of the sub-conveyor 52. However, since the filament assembly Fab on the collection belt 151 of the main conveyor 51 is sucked while intervening, it is kept low so as not to limit the movement of the collection belt 151 .

In the suction chamber 154b-2, following the suction chamber 154b, the suction pressure Pb-2 is set to, for example, a wind speed Pa of 1.2 when manufacturing a nonwoven fabric C with a basis weight of 65 g/m ² , and the basis weight is set to is set to Pa=3.2 when manufacturing a nonwoven fabric C with a weight of 15 g to 19 g/m ² . Here, the suction pressure (wind speed) Pb-2 maintains a sheet-like suction-held shape regardless of the basis weight (weighing weight) of the filament aggregates Fb and Fab, similarly to the suction pressure Pb. Since it is sandwiched between the collection belts 151 and 153 of the main conveyor 51 and the sub-conveyor 53 as it is, the value is suppressed to an extremely low value, and it is reliably sucked and held between the collection belts 151 and 153. The filament assembly F with a smaller basis weight is set to be strongly attracted so as to enter the . On the collection belt 151 of the main conveyor 51 under the sub-conveyor 53, the sheet-like filament assembly Fc collected and held by the collection belt 153 is sandwiched in a state of being superimposed on the sheet-like filament assembly Fab. It is sucked and held and transferred downstream.

The suction pressure Pc of the suction chamber 154c is set to Pa=6.3, for example, when manufacturing a nonwoven fabric C with a basis weight of 65 g/m ^{2 .} is set to Pa=7.4. Similar to the suction pressures Pa and Pb, the suction pressure (wind speed) Pc is set to a strong value regardless of the basis weight because the filament assembly Fc is collected and formed on the collection belt 153 of the sub-conveyor 53. However, since the filament assembly Fabc on the collection belt 151 of the main conveyor 51 is sucked while intervening, it is kept low so as not to limit the movement of the collection belt 151 .

The suction chamber 154c-2, following the suction chamber 154c, is set to have a suction pressure Pb-2 of Pa=1.2 to 3.8 when manufacturing a nonwoven fabric C with a basis weight of 65 g/m ² , for example, Also, Pa is set to 3.2 to 38 when manufacturing a nonwoven fabric C having a basis weight of 15 to 19 g/m ² . The suction pressure (wind speed) Pc-2 is set so that the collection belt 151 of the main conveyor 51 reliably sucks and holds the filament assembly Fabc carried out from under the sub-conveyor 53 and delivers it to the embossing device 60. It is set to be lower than the suction pressure Pa according to the basis weight.

By the way, as shown in FIG. 2, the filaments f spun from the injector 40 of the jetting device 10 are jetted onto collecting belts 151, 152, and 153 of the collecting conveyor 50 and collected as a sheet-like filament aggregate F. It is collected and formed into a nonwoven fabric. At this time, the filament f is pulled (stretched) by the injector 40 with high-pressure air, and is rotated in a small radius to form a sheet.

Therefore, as shown in FIG. 3, the injector 40 is provided with a pair of guide plates (adjustment means) 141 and 142 to adjust the rotation diameter fr of the filament f. The guide plates 141 and 142 are formed in plate shapes facing each other in the moving direction of the collection belt 151 of the main conveyor 51, and are installed. to adjust the rotation diameter fr of the filament f. The guide plates 141 and 142 collect the filaments f from the jetting devices 10A, 10B, and 10C at different circulating rotation diameters fr, for example, before the filaments f are ejected by the injector 40 (before the operation of the nonwoven fabric manufacturing apparatus 1 is started). The belts 151, 152, and 153 are set to be collected in sheets.

As a result, the filament assembly Fabc sucked and held by the collection belt 151 of the main conveyor 51 and transferred is shown in FIG. , or adjusted to a large diameter as shown in FIG. 3(b). be made C. At this time, the filament aggregates Fa, Fb, and Fc for each of the ejection devices 10A, 10B, and 10C are formed by stacking the filaments f repeatedly formed in circular shapes with different diameters into a sheet, thereby increasing the diameter. The nonwoven fabric C of the sheet-like filament assembly Fabc is formed in such a state that one of the different circular filaments f is entwined with the other.

Here, in the injector 40 of the present embodiment, before the operation of the nonwoven fabric manufacturing apparatus 1 is started, the opening interval Ld between the tip end portions 141a and 142a of the guide plates 141 and 142 is adjusted to inject into the collecting belts 151, 152 and 153. A case of setting the rotation diameter fr of the filament f to be attached will be described as an example, but the present invention is not limited to this. Specifically, during the spinning operation of the filaments f of the ejection devices 10A, 10B, and 10C, the opening distance Ld between the tip portions 141a and 142a of one or more sets of the guide plates 141 and 142 is changed (adjusted), The filaments f constituting the sheet-like filament assembly Fabc may be stacked in a tangled state as a whole, and the quality of the nonwoven fabric C can be easily adjusted.

As described above, in the nonwoven fabric manufacturing apparatus 1 of the present embodiment, a filament assembly in which the fibrous filaments f melted and ejected from the ejection devices 10A, 10B, and 10C arranged at three locations are bundled. Fa, Fb, and Fc are ejected onto and collected by collection belts 151, 152, and 153 of main conveyor 51 and sub-conveyors 52, and 53, respectively, to form a sheet, which is then sequentially stacked to form nonwoven fabric C. can be made.

At this time, the collection belts 152 and 153 of the sub-conveyors 52 and 53 are rotated in the opposite direction to the collection belt 151 of the main conveyor 51, so that the upper surfaces 152a and 153a are moved in the opposite direction and then reversed. By moving in the same direction while being sandwiched with the upper surface 151a, it is possible to form the sheet-like filament aggregates Fabc that are sequentially stacked.

Furthermore, the sheet-like filament aggregates Fa, Fb, and Fc on the collection belts 151, 152, and 153 of the main conveyor 51 and the sub-conveyors 52 and 53 are guided by the guide plates 141 of the injectors 40 of the ejection devices 10A, 10B, and 10C. , 142 are collected by adjusting the open space Ld between the tips 141a and 142a of the filaments f so that the diameters fr of the filaments f are different from each other. It is possible to form a sheet-like filament aggregate Fabc which is stacked in a state of being uncoordinated.

Therefore, the nonwoven fabric fabricating apparatus 1 can perform the nonwoven fabric fabricating method described above to fabricate a multi-layered nonwoven fabric C in which the sheet-like filament aggregates Fa, Fb, and Fc are laminated with high quality.

Here, in the above-described embodiment, a case where the pair of guide plates 141 and 142 are installed in the injector 40 to adjust the rotational diameter fr of the filament f ejected toward the collecting conveyor 50 will be described as an example. However, it is not limited to this.

For example, as shown in FIG. 4, a dispersing plate 145 may be installed in the injector 40 of the ejection device 10 to adjust the circulating rotation diameter fr of the filament f.

The distribution plate 145 is formed in a plate shape extending in a direction perpendicular to the moving direction D of the collection belt 151 of the main conveyor 51, and is installed upstream (or downstream) in the moving direction D. By changing the retraction interval Lr of the tip portion 145a from directly below the installation position, the rotation radius fr of the filament f is adjusted.

Specifically, the distribution plate 145 has an inclined surface 145 s that is spaced apart from directly below the ejection port as it goes downward from the installation position near the ejection port of the injector 40 . A space As is formed between the ejected filament f and the jet flow generated by dragging the surrounding air.

Therefore, the jet flow formed by the bundle F of the filaments f ejected from the injector 40 forms a negative pressure state in which a large suction force is generated as the distance from the inclined surface 145s of the dispersion plate 145 increases downward. Therefore, the liquid is discharged (sprayed) in a direction bent along the inclined surface 145 s of the dispersion plate 145 .

As a result, the filaments f that are spun from the injector 40 of the jetting device 10 while making a minute lap are jetted onto the collecting belts 151, 152, and 153 of the collecting conveyor 50 and collected as a sheet-like filament assembly F. When the non-woven fabric C is formed by , it can be bent by a suction force corresponding to the inclination angle of the inclined surface 145s of the dispersion plate 145, and the rotating diameter fr that rotates while being pulled (stretched) by the high-pressure air in the injector 40 is can be adjusted.

Here, the inclination angle of the dispersion plate 145 may be adjusted (set) before starting the operation of the nonwoven fabric manufacturing apparatus 1 as in the above-described embodiment, but the invention is not limited to this. During the spinning operation, the retraction interval Lr of the tip portion 145a of the dispersion plate 145 is changed (adjusted) so that the filaments f constituting the sheet-like filament aggregate Fabc are entirely overlapped in a further entangled state. and the quality of the nonwoven fabric C can be easily adjusted. Note that the dispersion plate 145 will be described with an example in which the inclined surface 145s is flat, but this is not restrictive. It may be formed so as to increase the negative pressure between them.

Further, for example, as shown in FIG. 5, a reflecting plate 147 may be installed in the injector 40 of the jetting device 10 to adjust the circulating rotation diameter fr of the filament f.

The reflecting plate 147 is formed in a plate shape extending in a direction perpendicular to the moving direction D of the collecting belt 151 of the main conveyor 51, and is installed upstream (or downstream) in the moving direction D. By changing the intersecting interval Lc of the tip portion 147a from directly below the installation position, the circulating rotation diameter fr of the filament f is adjusted.

Specifically, the reflecting plate 147 has an inclined surface 147s that intersects toward the installation side from directly below the ejection port as it goes downward from the installation position near the ejection port of the injector 40 . rebounds the filament f that is ejected directly below from and impinges thereon.

Therefore, the bundle F of the filaments f ejected from the injector 40 is ejected (injected) in a direction in which it bends (rebounds) more as the inclination angle of the inclined surface 147s of the reflector 147 increases.

As a result, the filaments f that are spun from the injector 40 of the jetting device 10 while making a minute lap are jetted onto the collecting belts 151, 152, and 153 of the collecting conveyor 50 and collected as a sheet-like filament assembly F. When forming the nonwoven fabric C, the filament f during micro-circulation is bounced back with a size corresponding to the inclination angle of the inclined surface 147s of the reflector 147, so that the circumference rotation diameter fr is varied. can do.

Here, the inclination angle of the reflecting plate 147 may be adjusted (set) before starting the operation of the nonwoven fabric manufacturing apparatus 1 as in the above-described embodiment, but the present invention is not limited to this. During the spinning operation, the intersecting distance Lc of the tip portion 145a of the reflector 147 is changed (adjusted) so that the filaments f constituting the sheet-like filament assembly Fabc are entirely overlapped in a further entwined state. and the quality of the nonwoven fabric C can be easily adjusted.

Further, for example, a static electricity applying device (not shown) may be provided for applying static electricity to the filament f ejected to the injector 40 of the ejection device 10 .

As shown in FIG. 6, this static electricity applicator applies positive or negative voltage-adjusted static electricity of the same polarity to the filament f ejected from the injector 40 to provide mutually repulsive electrostatic force, thereby making the filament f circulate. Adjust the rotation radius fr.

Therefore, the filament f ejected from the injector 40 tends to circulate while being spaced apart with a larger radius as the applied static electricity voltage increases.

As a result, the filament f spun from the injector 40 of the jetting device 10 while being finely circulated is separated from the collecting belt 151, It is sprayed onto 152 and 153 and collected as a sheet-like filament assembly F to form a nonwoven fabric C. FIG.

The voltage of this static electricity may be adjusted (set) before starting the operation of the nonwoven fabric manufacturing apparatus 1 as in the above-described embodiment, but is not limited to this. It may be changed (adjusted) so that the filaments f constituting the sheet-like filament assembly Fabc are stacked in a tangled state as a whole, and the quality of the nonwoven fabric C can be easily adjusted.

Next, FIG. 7 is a diagram showing a nonwoven fabric manufacturing apparatus for executing the nonwoven fabric manufacturing method according to the second embodiment of the present invention. Here, since this embodiment has substantially the same configuration as the above-described embodiment, the same reference numerals are assigned to the same configurations, and the characteristic portions will be described.

7, the nonwoven fabric production apparatus 2 includes three sets of ejection devices 10 (10A, 10B, 10C), a collecting conveyor (sheet conveying device) 50, and an embossing device 60, similarly to the nonwoven fabric production device 1 described above. , and a winder 70, which are arranged in series so as to be able to execute various processes.

The collection conveyor 50 in this embodiment is constructed by including a main conveyor 51 and a suction box 54 without installing a sub-conveyor.

Since the main conveyor 51 is not provided with the sub-conveyors 52 and 53, the upper surface 151a of the collection belt 151 carries the filament aggregates Fa, Fb, and Fc pulled down by the injectors 40 of the ejection devices 10A, 10B, and 10C. They function as a collecting surface and a conveying surface that sequentially collect and transfer in a sheet form, respectively.

For this reason, the collection belt 151 of the main conveyor 51 allows the filament aggregates Fa, Fb, and Fc spun by the ejection devices 10A, 10B, and 10C to be drawn onto the upper surface 151a by the suction chambers 154a, 154b, and 154c of the suction box 54, respectively. It is formed into a sheet shape by being directly sprayed and collected by suction.

At this time, first, after the filament assembly Fa is collected and formed in a sheet shape on the collection belt 151 by the suction force of the suction chamber 154a, it is held by the suction force of the suction chamber 154a-2 adjacent to the downstream side. be transported. Subsequently, after the filament assembly Fb is directly collected on the sheet-like filament assembly Fa by the suction force of the suction chamber 154b in a sheet form to form the sheet-like filament assembly Fab, similarly, downstream It is transferred while being held by the suction force of the side adjacent suction chamber 154b-2. Furthermore, after the filament assembly Fc is directly collected on the sheet-like filament assembly Fab by the suction force of the suction chamber 154c in a sheet form to form the sheet-like filament assembly Fabc, similarly, It is transferred while being held by the suction force of the adjacent suction chamber 154c-2.

As a result, the collecting conveyor 50 directly sucks and collects the filament aggregates Fa, Fb, and Fc spun by the ejection devices 10A, 10B, and 10C onto the collecting belt 151 into sheets of a predetermined thickness by means of the suction box 54. By holding the sheet-like filament aggregates Fabc (nonwoven fabric C) before embossing, the filament aggregates Fabc (nonwoven fabric C) before embossing can be conveyed downstream and transferred to the embossing device 60 .

The sheet-like filament assembly Fabc on the collection belt 151 of the collection conveyor 50 is spun by the ejection devices 10A, 10B, and 10C to form the filament assemblies Fa, Fb, and Fc. By adjusting the rotational diameter fr by changing the opening distance Ld on the tip end side of the pair of guide plates 141 and 142, when collecting in a sheet form on the collection belt 151, circular shapes with different diameters are repeatedly formed. The nonwoven fabric C is formed in a state in which the filaments f are entangled.

As described above, in the nonwoven fabric production apparatus 2 of the present embodiment, a filament assembly in which the fibrous filaments f melted and ejected from the ejection devices 10A, 10B, and 10C arranged at three locations are bundled. Fa, Fb, and Fc are ejected directly onto the collection belt 151 of the main conveyor 51, collected in a sheet form, and stacked one after another to produce the nonwoven fabric C. As shown in FIG.

The sheet-like filament assembly Fabc on the collecting belt 151 of the main conveyor 51 can be formed into a sheet by directly entangling the filaments f of the filament assemblies Fb and Fc to be stacked on the underlying filament f. It is possible to avoid forming between layers with different quality by entangling them with uniform quality in the direction.

Therefore, the nonwoven fabric fabricating apparatus 2 can perform the nonwoven fabric fabricating method described above to fabricate a multi-layered nonwoven fabric C in which the sheet-like filament aggregates Fa, Fb, and Fc are laminated with high quality.

Here, also in this embodiment, instead of the pair of guide plates 141 and 142, the dispersing plate 145, the reflecting plate 147, or a static electricity applying device (not shown) may be installed.

The scope of the invention is not limited to the illustrated and described exemplary embodiments, but also includes all embodiments that provide equivalent results for which the invention is intended. Furthermore, the scope of the invention is not limited to the combination of inventive features defined by each claim, but may be defined by any desired combination of the particular features of each of the disclosed features. .

1, 2...Nonwoven fabric production devices 10, 10A, 10B, 10C...Ejection device 20...Spinning device 30...Cold air device 40...Injector 50...Collection conveyor 51...Main conveyors 52, 53...Sub Conveyor 54 Suction box 60 Embossing device 70 Winders 141, 142 Guide plates 151, 152, 153 Collection belts 154a, 154b, 154c Suction chamber C Nonwoven fabric f Filaments fr... Rotational diameter F, Fa, Fab, Fabc, Fb, Fc... Filament assembly Lc... Crossing interval Ld... Open interval Lr... Retreat interval P, Pa, Pb, Pc, Pe, Pm, Ps... … Suction pressure (wind speed)

Claims (6)

A fiber spraying device for blowing out a bundle of fibrous filaments ejected by melting a thermoplastic resin; A nonwoven fabric manufacturing apparatus comprising a sheet conveying device that conveys in a conveying direction while
The fiber jetting device has adjusting means for adjusting the rotation diameter of the filaments when the filaments are jetted onto the conveying surface of the sheet conveying device while rotating around the discharge direction. A nonwoven fabric fabricating apparatus characterized by being arranged at a plurality of locations in a conveying direction of a conveying surface. 2. The nonwoven fabric fabricating apparatus according to claim 1, wherein said adjusting means has a function of adjusting the rotational diameter of said filaments during ejection by said fiber jetting device. The sheet conveying device includes suction means for holding the sheet-like filament by sucking the upper surface side from below the conveying surface,
The suction means is characterized in that the suction pressure at a position where the bundle of filaments is jetted by the fiber jetting device is adjusted to be higher than the suction pressure at the downstream side of the jetting position in the conveying direction. The nonwoven fabric manufacturing apparatus according to claim 1 or 2. The suction means has a suction pressure Ps>Pm and Pe, where Ps is the leading suction pressure in the transfer direction of the sheet conveying device, Pe is the last suction pressure in the transfer direction, and Pm is the intermediate suction pressure in the transfer direction. >Pm. 5. The nonwoven fabric manufacturing apparatus according to claim 3, wherein the suction pressure of said suction means is adjusted according to the basis weight of said sheet-like filaments. A method for producing a nonwoven fabric in which a fibrous filament that is melted and discharged from a thermoplastic resin is bundled and ejected toward a conveying surface and collected to form a sheet-like nonwoven fabric and conveyed in a conveying direction,
A method for producing a nonwoven fabric, characterized in that, when the filaments are collected by being sprayed at a plurality of locations in the transport direction of the transport surface, the filaments are entangled with the upstream side by varying the rotation diameter of the filaments to make a nonwoven fabric. .

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