JPH05209351A - Nonwoven sheet and its production - Google Patents

Abstract

PURPOSE:To obtain a nonwoven sheet having uniform fiber distribution without dropping out of fibers and easily and cheaply producible, and its production. CONSTITUTION:As a nonwoven sheet is constructed with a wide width fiber belt So in which a large number of long yarns line in the same direction and combination fibers Ks arranged on the surface of the fiber belt So continuously and crosswise to each fiber and entangled to each of the said fibers, only a small amount of fibers is needed for the combination fibers Ks, thus cheaply forming the nonwoven sheet itself with cutting down a material. Further, as each fiber in the fiber belt So is combined in belt state, separation and dropping out of each of the said fibers can be completely prevented. Thus, the objective nonwoven fabric can be produced by a simple method by setting the combination fibers on the surface of the wide width fiber belt and combinating both fibers together.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-woven sheet made of fibers and a method for producing the non-woven sheet.

[0002]

2. Description of the Related Art Nonwoven sheets of this kind are widely used in various fields as ventilation filters, soundproofing materials, reinforcing materials and the like. Is embedded in another sheet base material.

In the former non-woven sheet, a large number of fibers of a predetermined length made of metal, glass or the like are gathered and the aggregate is formed into a sheet by a roller or a press (dry method). Alternatively, the fibers are dispersed in a liquid such as water or alcohol, and the dispersion is sucked through a gas permeable mold to remove the liquid content and form the fibers into a mold into a sheet (wet method). It is manufactured by A needle punch is usually applied to each of the sheet-shaped products after the molding to enhance the entanglement of the fibers to strengthen the binding force.

In the latter non-woven sheet, fibers similar to the above are sprinkled on a sheet base material such as woven cloth or non-woven cloth, and the sprinkled fibers are embedded in the sheet base material by a needle punch. Is manufactured in.

[0005]

However, since the conventional non-woven sheets all use relatively short fibers as a material, there is a drawback that the fibers easily separate and fall off over time. In particular, the former non-woven sheet requires a large amount of fibers and the process contents are difficult, resulting in poor productivity and
There is a drawback that the device itself becomes expensive.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a non-woven sheet and a method for producing the same which can prevent separation and dropping of fibers and can be easily and inexpensively produced. The purpose is to provide.

[0007]

In order to achieve the above object, according to claim 1, a wide fiber band in which a large number of long fibers are lined up in substantially the same direction and each fiber intersects on the surface of the fiber band and The non-woven sheet is composed of the fibers for bonding which are continuously arranged and are bonded to each other.

Further, in claim 2, a step of crushing a fiber bundle composed of a large number of long fibers in the radial direction to produce a wide fiber band in which the respective fibers are arranged in substantially the same direction, and A non-woven sheet is produced from a step of continuously attaching bonding fibers to the surface of the fiber band so as to intersect each fiber and a step of bonding each fiber of the fiber band and the bonding fiber to each other. is doing.

[0009]

The non-woven sheet according to claim 1 is mainly composed of a wide fiber band in which a large number of long fibers are arranged in substantially the same direction, and each fiber of the fiber band is bonded by a bonding fiber. Therefore, the amount of fibers required as the bonding fibers is small, and the fibers in the fiber band can be bonded in a band shape.

In the method for producing a non-woven sheet according to a second aspect of the present invention, the above-mentioned non-woven sheet is obtained by a simple method in which bonding fibers are attached to the surface of a wide fiber band and both fibers are bonded together. See
Can be manufactured appropriately.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a non-woven sheet manufactured by the manufacturing method described later. The non-woven sheet Fs is made of stainless fiber having a thickness of about 50 μm, and has a wide fiber band So in which a large number of long fibers are arranged in substantially the same direction and an upper surface of the fiber band So. It is composed of one binding fiber Ks which meanders at the width interval and is continuously arranged. The fiber band So has a predetermined thickness as a sheet, and each fiber of the fiber band So and the bonding fiber Ks are intertwined with each other and bonded. The non-woven sheet Fs is cut in the length direction of the fiber band So and used as a ventilation filter, a soundproofing material, a reinforcing material, or the like.

The above-mentioned non-woven sheet Fs has a step of obtaining a fiber bundle St, a step of obtaining a wide fiber band So from the fiber bundle St, and a meandering bonding fiber Ks on the upper surface of the fiber band So. Attaching step, bonding step of bonding fiber Ks to the upper surface of fiber band So, and each fiber of fiber band So and bonding fiber Ks
It is manufactured through the process of intertwining with each other.

The above steps will be described below with reference to FIGS. 2 to 6 together with an apparatus preferably used for each step.

FIG. 2 shows a cutting machine 1 for producing a fiber bundle St.
And a spreader 11 for generating a wide fiber band So from the fiber bundle St.

In the cutting machine 1, a rotary shaft 4 is rotatably supported by a pair of bearing bases 3 arranged at intervals on a base 2, and one bearing base 3 drives the rotary shaft. It has a built-in motor 5. A winding portion 4a having a circular cross section and having the same axis as the axis J of the rotating shaft 4 is provided at the center of the rotating shaft 4.
Engaging grooves 4b are formed in parallel with the axis J on the surface of a, and a thin metal plate 6 made of stainless steel as a cutting material is wound around the winding portion 4a. The thin metal plate 6 has a thickness of 50 μm, and after inserting the edge into the engaging groove 4b, it is tightly wound many times in the clockwise direction in the figure while rotating the rotary shaft 4, and the other edges are welded. , It is fixed by adhesion.

A guide rail 7 is arranged on the base 2 in parallel with the rotary shaft 4, and a tool rest 9 equipped with a cutting blade 8 is slidably engaged with the guide rail 7. The cutting blade 8 has an extension line E of the cutting line orthogonal to the axis line J of the rotary shaft 4, and the cutting line is formed by the metal thin plate 6
It is located at the center of the height direction. This turret 9 has a button
A nut 9a for a thumb screw is vertically installed and screwed with a ball screw 10 which is motor-driven in the base 2.

When the fiber bundle Ss is produced by the above cutting machine 1, the motor 5 is operated to rotate the rotary shaft 4 counterclockwise in the figure at a constant speed, and the ball screw 10 is used. Is rotated in a predetermined direction to slightly feed the tool rest 9 toward the thin metal plate 6 at a constant speed. When the cutting blade 8 comes into contact with the end surface of the thin metal plate 6 by the movement of the tool rest 9, the end surface is cut in the circumferential direction, and thereafter, a large number of metal fibers are continuously bundled in a bundle according to the feed amount of the cutting blade 8. Is generated. As shown in the schematic cross section of FIG. 3, the fiber bundle St generated here has a fiber length of more than 60 mm per fiber and a thickness substantially corresponding to the thickness of the thin metal plate 6. ..

The spreader 11 is composed of a pair of rollers 12 arranged vertically with a predetermined interval, and a drive mechanism (not shown) for rotating the rollers 12 in opposite directions. And faces the cutting position of the cutting machine 1.

When the fiber bundle St is spread by the spreader 11, the fiber bundle St generated by the cutting machine 1 is inserted between the rollers 12 and the drive mechanism is operated. Roller 1
The fiber bundle St inserted between the two rollers is crushed in the radial direction by both rollers 12, and spreads laterally in a band shape with a thickness corresponding to the interval defined between the rollers 12. The fiber band So generated here has a substantially constant thickness as shown in the schematic cross section in FIG. 4, and the fibers are arranged in substantially the same direction.

FIG. 5 shows a fiber attaching machine 21 for attaching the binding fibers Ks to the upper surface of the fiber band So.

In the fiber attaching machine 21, a guide shaft 24 is erected on a pair of support plates 23 which are opposed to each other on the base 22 with a predetermined space therebetween, and a ball screw 25 is rotated in parallel with the guide shaft 24. It is rotatably supported, and one support plate 23 has a motor 26 for rotating a ball screw.
Further, on the base 22 between the support plates 23, a plurality of guide rollers 22a for sliding the fiber band So in a predetermined direction are arranged in parallel.

A slider 27 is slidably engaged with the guide shaft 24 through a slide bush or the like, and a nut 27a provided on the slider 27 is screwed into a ball screw 25. Further, the support rod 2 is provided on the upper surface of the slide 27.
7b is erected, and a bobbin 28 around which the binding fiber Ks is wound is rotatably inserted. This binding fiber Ks
Like the fiber band So, is made of stainless fiber having a thickness of about 50 μm. Although not shown, both support plates 23 are provided with limit switches for switching the reciprocating width of the slider 27, that is, the rotating direction of the motor 26, corresponding to the width of the fiber band So.

A U-shaped bracket 28 is attached to one side of the slider 27, and a pair of feed rollers made of rubber for feeding the connecting fiber Ks downward is attached to the bracket 28.
A roller 29 and a motor 30 for rotating one of the feed rollers 29 in a predetermined direction are provided. The feed rollers 29 mesh gears 29a provided on the feed rollers 29, respectively, and rotate in opposite directions by the rotation of the motor 30 to feed the binding fibers Ks downward.

When the binding fiber Ks is attached to the upper surface of the fiber band So by the above-mentioned fiber attachment machine 21, the binding fiber Ks is inserted between the feed rollers 29 and both motors 2 are inserted.
6 and 30 are operated to move the fiber band So onto the roller 22a at a constant speed. When the motor 26 operates, the slider 2
7 moves along the guide shaft 24 in either the left or right direction at a constant speed, and when the slider 27 contacts the limit switch, the motor 26 rotates in the opposite direction. That is, the slider 27 reciprocates corresponding to the width of the fiber band So defined by the limit switch. Further, when the motor 30 is operated, the feed rollers 29 rotate in mutually opposite directions, and the binding fibers Ks are pulled out from the bobbin 28 and fed downward. That is, the binding fibers Ks meander at the width intervals and are continuously placed on the upper surface of the fiber band So.

FIG. 6 shows a pressure welding machine 31 for bringing the binding fibers Ks into close contact with the upper surface of the fiber band So, and a binding machine 41 for intertwining each fiber of the fiber band So and the binding fiber Ks with each other. ..

The press-connecting machine 31 is composed of a pair of rollers 32 arranged vertically with a predetermined interval, and a drive mechanism (not shown) for rotating the rollers 32 in mutually opposite directions. And faces the delivery position of the fiber attachment machine 21.

In performing the pressure welding with the above-mentioned pressure welding machine 31, the fiber band So on which the binding fiber Ks is placed is rolled by the roller 3.
Insert it between the two and activate the drive mechanism. The binding fiber Ks and the fiber band So inserted between the rollers 32 are pressed against each other by the two rollers 12 and adhere to each other. This pressure welding machine 31
Is used for the purpose of bringing the binding fiber Ks into close contact with the fiber band So, and does not affect the size of the fiber band So.

The coupling machine 41 comprises a jig 42 having a large number of J-shaped needles 42a, a drive mechanism (not shown) for moving the jig 42 up and down, and a pedestal (not shown). It faces the delivery position of the pressure welding machine 31.

In performing the bonding with the above-mentioned bonding machine 41, the jig 41 is provided with the fiber band So to which the bonding fibers Ks are closely attached.
To the lower side to activate the drive mechanism. The moving fiber band So is subjected to needle punching by a vertically moving needle 42a, and each fiber of the fiber band So and the bonding fiber Ks are entwined with each other and bonded. As described above, the non-woven sheet Fs shown in FIG. 1 is manufactured.

Since the non-woven sheet Fs requires a small amount of fibers as the binding fibers Ks, the non-woven sheet Fs itself can be formed at a low cost by reducing the number of materials. In addition, the fibers K of the bonding band can bond the respective fibers of the fiber band So in a band-like shape to reliably prevent separation and drop-off of the respective fibers.

The fibers constituting the non-woven sheet may be metal fibers other than stainless steel or glass fibers,
The fiber diameter may be variously changed depending on the application. Also, 1
When a sufficient width as a sheet cannot be obtained with one fiber band, a plurality of fiber bundles may be collectively spread into one bundle, or a plurality of spread fiber bands may be arranged and used. ..

Although the fiber bundle obtained by a coil cutting machine is shown, long fibers produced by a device other than the cutting machine may be bundled and used as a fiber bundle.

Further, although the bonding fiber is attached only to one surface of the fiber band, the bonding fiber may be similarly attached to the other surface to perform niddle punching. Besides being attached in a meandering shape, it may be spirally wound around the surface of the fiber band. Further, the attachment pitch of the binding fibers can be appropriately changed according to the desired strength, and the binding force between each fiber of the fiber band and the binding fibers can be increased by reducing the pitch.

Furthermore, not only one binding fiber,
It is possible to attach more than one at the same time, or
It may be attached to Mie.

Furthermore, although the needle punch is used to connect the fibers of the fiber band and the connecting fiber, a sintering method or the like may be used instead of the needle punch. You may use together.

[0036]

As described in detail above, according to the non-woven sheet of the first aspect, a large number of long fibers are mainly formed of wide fiber bands arranged in substantially the same direction. Since each fiber is composed of the bonding fibers, the amount of fibers required as the bonding fibers is small, and the non-woven sheet itself can be formed at a low cost by reducing the number of materials. Moreover, since the fibers of the fiber band can be bonded by the bonding fibers in a band-like shape, it is possible to reliably prevent separation and drop-off of the fibers of the fiber band.

According to the non-woven sheet manufacturing method of the present invention, a binding fiber is attached to the surface of a wide fiber band, and both fibers are bonded to each other by a simple method. The above-mentioned nonwoven sheet can be appropriately manufactured.

[Brief description of drawings]

FIG. 1 is a top view of a non-woven sheet according to the present invention.

FIG. 2 is a perspective view of a cutting machine and a spreading machine.

FIG. 3 is a schematic sectional view of a fiber bundle.

FIG. 4 is a schematic sectional view of a fiber band.

FIG. 5 is a perspective view of a fiber attachment machine.

FIG. 6 is a perspective view of a pressure welding machine and a coupling machine.

[Explanation of symbols]

Fs ... nonwoven sheet, So ... fiber band, Ks ... bonding fiber,
St ... Fiber bundle, 1 ... Cutting machine, 11 ... Spreading machine, 21 ... Fiber installation machine, 31 ... Pressure welding machine, 41 ... Bonding machine.

Claims (2)

[Claims] 1. A wide fiber band in which a large number of long fibers are arranged in substantially the same direction, and a plurality of long fibers are arranged on the surface of the fiber band so as to intersect each fiber and continuously.
A non-woven sheet comprising: each of the fibers and a bonding fiber that bonds with each other. 2. A step of crushing a fiber bundle composed of a plurality of long fibers in its radial direction to form a wide fiber band in which the fibers are arranged in substantially the same direction, and intersecting each fiber of the fiber band. Thus, the non-woven sheet is characterized in that it comprises a step of continuously attaching binding fibers to the surface of the fiber band, and a step of mutually binding each fiber of the fiber band and the binding fiber. Manufacturing method.