JPH03279456A - Production of fibrous mat - Google Patents

Abstract

PURPOSE:To obtain at reduced cost a lightweight fibrous mat with partially increased mechanical strength by metering a fibrous material using plural instruments installed dividedly in the cross direction of conveyor to regulate the cross direction distribution of the weight of the material. CONSTITUTION:A fibrous material 1 is metered using plural instruments 14 provided dividedly in the cross direction of a conveyor 11, thus enabling the cross direction distribution of the feed of the material 1 to be regulated. Also, the clearance between the edge wheels of an opener 16 is varied crosswise corresponding to the feed of the material 1, thus enabling even opening as a whole irrespective of the feed of the material from the viewpoint of its cross direction distribution, and finally obtaining the objective fibrous mat with the weight proportional to the feed of the material.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for producing fiber mats, particularly fiber mats used as interior materials for automobiles.

(Prior Art) Conventionally, fiber mats used for automobile interior materials have been manufactured by an air-lay method, a card cloth layer method, or the like.

FIG. 1 schematically shows the manufacturing process of a fiber mat using a cross-layer method. The fiber material 1 for forming the fiber mat is usually a roving-like or cotton-like block, and the fiber material 1 is placed on a conveyor 2 and introduced into a cutter 3 to a certain length, usually 25 to 1.
It is cut to a length of about 0.00 mm. The cut fibrous material 1 is sent to a cotton blending machine 5, where various fibrous materials are mixed.Then, the blended fibrous material 1 is sent under pressure to a stocker 8 through a duct 7 by a cotton feeding machine 6.

The fiber material in the stocker 8 is continuously fed onto a conveyor 9 and sent to an up lattice conveyor 11, where it is remixed in this process. The fiber material 1 moving up the up lattice conveyor 11 is adjusted to an appropriate amount by a scraper 12 and then supplied to a measuring device 14 . A predetermined amount of the fiber material l accumulated in the measuring device 14 is dropped onto a lattice conveyor 15 and supplied to a fibrillator 16. In the defibrating machine 16,
Cylinder 17, walker 18 and stripper 19
There are cylindrical blade wheels, and the fiber material 1 is passed between them to be defibrated. The fiber material coming out of the defibrator 16 is made into a web-like fiber layer 21 and then transferred to a lattice conveyor 2.
The cross layer 23 reciprocating in the width direction above the lattice conveyor 22 is dropped onto the lattice conveyor 22 to form a laminate 24 folded in a zigzag pattern. This laminate 24 is pressed on a lattice conveyor 22.25 to a thickness of about 150 mm,
Needle bunching is performed in a needle locker 27. As a result, the fibers of each layer are entangled with each other to form a fiber mat 30 with a thickness of about 10 mm. The fiber mat 30 is edge-trimmed by a cutter 28 and then cut by a rotary cutter so as to be wound around a roller 31 to an appropriate length.

The fiber mats produced in this way are used, for example, in automobile trunk compartment lining materials, and ceiling materials made by impregnating and hardening resins.

(Problems to be Solved by the Invention) For fiber mats used in automobiles, there is a demand for fiber mats that are made thicker only in specific portions such as fixing portions and component attachment portions, thereby increasing the strength of the portions. In particular, fiber mats manufactured with a large basis weight on both sides are often requested.

However, in the above-mentioned conventional method for producing fiber mats,
Weighing and defibration are performed using a measuring device 14 having a width corresponding to the width of the fiber material 1 continuously conveyed by the conveyor 11 and a defibrator 16 having the same width. Since the distribution in the width direction cannot be adjusted, it is not possible to produce a fiber mat with a different basis weight in the width direction, for example, a mat in which the basis weight of both side parts is increased to increase the strength of that part.

In addition, manufacturing a fiber mat with a large overall basis weight for a part that requires strength means that more fiber material is used than necessary, making the fiber mat expensive. Moreover, the weight increases, making handling difficult.

The present invention has been made for the purpose of solving the above problems, and the problem to be solved is to control the width direction distribution of the amount of fiber material supplied in the so-called card cross layer one type fiber mat manufacturing method. An object of the present invention is to provide a method for manufacturing a fiber mat having partially different basis weights by adjusting the amount.

(Means for Solving the Problems) The method of manufacturing fiber mats having partially different basis weights according to the present invention is as follows. In other words, the fiber material that is continuously conveyed by a conveyor in a predetermined width is weighed and supplied to a defibrator, and the fiber mat is created through a process of laminating the web-like fiber layers of the defibrated fiber material in a cross layer. In the manufacturing method, the above-mentioned measurement is performed using a plurality of measuring devices installed separately in the width direction of the conveyor, and the clearance between the blade wheels of the defibrator is adjusted in response to the difference in the amount of fiber material supplied due to the difference in these measurements. This method is to vary it in the width direction.

In the present invention, a plurality of measuring devices are installed in order to measure the fiber material by dividing it in the width direction of the mat to be manufactured. - The width of each measuring device is preferably 200 to 500 + nm, and the number of measuring devices to be installed is determined depending on the length of the target fiber mat in the width direction. The installed scales each weigh a predetermined amount, and after the lid weighing is completed, the fiber materials in each scale are sent to the fibrillator at the same time.

Furthermore, it is necessary to install the same number of devices (up lattice conveyor, scraper, etc.) for supplying the fiber material to the scales according to the width of the divided scales. Multiple scales installed in the width direction, up lattice conveyors, scrapers, etc.
It is preferable to install them so that the phases in the material flow direction are alternately changed so that no gaps are created between the individual pieces.

In order to change the clearance between the blade wheels (cylinder, walker, stripper, etc.) of the defibrator in the width direction in response to the amount of fiber material supplied, for example, it is necessary to change the diameter of each blade wheel of the defibrator for each part. Multiple walkers and/or strippers divided in the width direction can be combined into a cylinder at appropriate distances, and the clearance between the blade wheels is large enough to provide a large amount of fiber supply so that the amount of fibrillation can be done in proportion to the amount of fiber supplied. It is made larger in areas where the amount of fiber supplied is smaller, and smaller in areas with less fiber supply.

The raw fiber material used in the present invention is a roving-like or cotton-like organic or inorganic fiber. In the case of manufacturing a glass fiber mat, glass fiber alone may be used, but organic fibers such as polyethylene fibers may be used as bonding fibers in the amount of 5 to 20%.
% mixing is preferred.

(Function) If the measurement is carried out using a plurality of measuring devices that are divided and provided in the width direction of the conveyor, it becomes possible to adjust the width direction distribution of the amount of fiber material supplied. By changing the clearance between the blade wheels of the defibrator in the width direction in accordance with the amount of fiber material supplied, the overall distribution is uniform regardless of the amount of fiber material supplied in the width direction. Defibration is achieved and a fiber mat is finally obtained with a basis weight proportional to the amount of fiber material supplied.

(Example) Hereinafter, an example of the method for manufacturing a fiber mat of the present invention will be described using the drawings.

Example 1 The entire manufacturing process of the fiber mat of this example is as shown in Figure 1, which includes inputting materials, cutting materials to size, blending, transporting, remixing, and
It consists of weighing, defibrating, laminating, needle punching, edge trimming, cutting, and winding processes, and is almost the same as the conventional card cross layer manufacturing method explained earlier, so here we will introduce a method that differs from the conventional method. The explanation will focus on the points.

In this example, in order to manufacture fiber mats having partially different basis weights, the measuring device and defibrating machine used are devised. In conventional fiber mat manufacturing equipment, the second
As shown in Figures (B) and (C), the scale 14
There was one up lattice conveyor 11 for supplying the fiber material 1 to the measuring device 14, and one up lattice conveyor 11 for supplying the fiber material 1 to the measuring device 14, but in this embodiment, as shown in FIG.

14c and 14d, and the corresponding up lattice conveyors are also lla, llb, llc and li.
It is divided into four parts, d.

The fiber material is transported by a divided up lattice conveyor 11a,
It is conveyed from llb, llc, and lid to similarly divided measuring instruments 14a, 14b, 14c, and 14d, and is then scraped in appropriate amounts by a number of scrapers (not shown) provided corresponding to each divided conveyor. It is adjusted and supplied. Each measuring device 14a, 14b, 1
4c and 14d are configured to measure individually determined amounts. Individual scales 14a, 14b, 1
If even one of 4c and 14d is not measured within a predetermined time, it is electrically detected and the equipment is stopped. When all scales have been weighed, the weighed fiber material is fed to the defibrator by a conveyor.

The main parts of this defibrator are a cylindrical cylinder 17, a walker 18, and a stripper 1, as shown in FIG. 3(A).
It consists of nine blade wheels, each of which has a large number of teeth (claw-like blades) on its surface for loosening the fibers. The fibrous material and material are attached to these rotating cylinders 17 and walker 1.
8 and the stripper 19 while being defibrated.

Conventionally, in this type of defibrating machine, the clearance between the cylinder 17 and the walker 18 (or the stripper 19) was fixed, but here, as shown in Fig. 18 and Stritz 5-19 are used, and the blade wheel clearances at the center part and both side parts of the defibrator are set to a and b, respectively.For this reason, the fibers are sent to the defibrator less in the center part and more in both side parts. There is also a method of changing the diameter of the cylinder 17 between a part of the center and a part of both sides as a method of adjusting the clearance, which does not cause any trouble in defibrating even when the fibers are supplied.

The defibrated fiber material is then converted into a mat as usual, and the final thickness of the center portion is t, as shown in FIG.
Thus, a fiber mat having a thickness of tb on both sides is obtained.

Example 2 In Example 1, the measurement was adjusted using a scraper, but in this example, the adjustment was performed exclusively on each conveyor lla and llb.

11c, lld (The ocher 18 and stripper 19 of the defibrator 16, which adjust the metering by varying the advancing speed in Fig. 2 (see Al), are also divided into parts in the same way as the measuring device, and their cylinders 17 The clearance between the mat and the mat is automatically controlled by detecting the speed of the conveyor. With this method, it is possible to manufacture mats with different area weights in various parts without modifying the mat manufacturing equipment. .

(Effects of the Invention) As is clear from the above description, according to the present invention, the basis weight of the mat manufactured using one card cloth layer method can be freely adjusted in the width direction distribution. Various types of fiber mats can be manufactured, such as mats with improved strength or mats that maintain strength only in necessary parts of the mat and reduce weight in other parts to reduce cost and weight.

[Brief explanation of the drawing]

Figure 1 is an explanatory diagram of the fiber mat manufacturing process using one type of card cloth layer, Figure 2 (Al is an explanatory diagram of the measuring mechanism of the mat manufacturing equipment used in one example, (C) is an explanatory diagram of the metering mechanism of a conventional manufacturing device; Figure 3 (Al and fBl are diagrams schematically showing the main parts of a fibrillator used in one embodiment; Figure 4 is an illustration of one embodiment) It is a perspective view showing a fiber mat obtained by. In the figure: 1... Fiber material 11... Up lattice conveyor 12... Scraper 14... Measuring device 16
...Defibrator 17...Cylinder 18...
Walker 19... Stripper 21... Web-like fiber layer 23... Cross layer 30...
・Fiber mat

Claims (1)

[Claims] A fiber mat is produced by weighing the fiber material that is continuously conveyed by a conveyor in a predetermined width and feeding it to a defibrator, and then laminating the web-like fiber layers of the defibrated fiber material in a cross layer. In this method, the measurement is performed using a plurality of measuring devices that are divided in the width direction of the conveyor, and the clearance between the blade wheels of the defibrator is adjusted in the width direction in response to the difference in the amount of fiber material supplied due to the difference in these measurements. A method for producing fiber mats having partially different basis weights, the method comprising: