JPH08269860A - Production of multilayer felt fleece and apparatus therefor - Google Patents

Abstract

PURPOSE: To obtain a multi-layered felt fleece capable of easily giving, at a low cost, a multi-layered felt made up of plural layers differing in properties or characteristics from one another, and also having a potential to greatly expand its use as felt product because of favorable interlaminar bonded state. CONSTITUTION: This apparatus for producing multilayer felt fleeces is so designed that plural rotary cylinders 2a, 2b each implanted with carding needles 1 on its circumferential surface are juxtaposed transversely, there are independently provided respective means 3a, 3b to feed felt materials A, B to the rotary cylinders 2a, 2b, both sides of a group of the rotary cylinders are respectively provided with the surface of conveyer belts 7, 7 mutually downwardly inclined inward, there is afforded a space for felt material scattering under the group of the cylinders, and a partition plate 4 free to have downward length is provided between the cylinders adjacent to each other and into the space.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a multi-layered felt fleece having a multi-layer structure having different compositions in a fleece which is a mixture of fibers, resins and the like used as a felt raw fabric.

[0002]

2. Description of the Related Art Conventionally, felts having a multi-layer structure have been manufactured by applying felts having a single composition.

However, with such a manufacturing method, manufacturing a felt having a multi-layer structure requires a lot of man-hours and is very disadvantageous in terms of cost. Further, since the adhesive layer is interposed, it has a poor feel such as being hard and having a feeling of bottoming, and is also disadvantageous in terms of physical properties including sound absorption.

[0004]

As a result of intensive studies to solve these problems, the present invention has developed a manufacturing method and apparatus for easily obtaining a multi-layered felt fleece by a simple method.

That is, according to the manufacturing method of the present invention, the felt material is separately scattered into the felt material scattering space by using a plurality of rotating cylinders in which a scraping needle is planted on the peripheral side surface, and thereafter, the felt material scattered matter is dispersed. Obtaining a multi-layered fleece in which each felt material is mixed at the boundary portion by mixing the boundary portion with the adjacent scattered material and pressing from the lower part of the scattering space in the stacking direction of each felt material scattered material It is characterized by.

Further, in the manufacturing apparatus of the present invention, a plurality of rotary cylinders in which scraping needles are planted on the peripheral side surface are arranged side by side in a lateral direction, and a supply means for supplying a felt material to each of the rotary cylinders is separately provided and arranged side by side. On both sides of the rotating cylinder group, conveyor belt surfaces inclined inward toward each other are provided downward, and a felt material scattering space is provided below the rotating cylinder group, and between the rotating cylinders, the felt material scattering space is provided. It is characterized in that it is provided with a partition plate whose length can be freely downward, in which case it is effective to make the conveyor belt surface breathable and to provide a suction duct on the back side of the conveyor belt surface. .

That is, in the device of the present invention, for example, as shown in FIG. 1, two rotating cylinders (2a) and (2b) having a scratch needle (1) uniformly planted on the surface thereof are installed in parallel, and the cylinders are placed laterally. A raw material supply belt conveyor (3a) in which a felt material composed of natural fibers, chemical fibers and synthetic resin or natural resin such as heat-sealing fibers or phenolic resin as a binder, and filler such as urethane foam is charged in different compositions. ) (3b), respectively. Then, the left and right different raw materials A and B sent by the raw material supply conveyors (3a) and (3b) are unraveled by the scratching needle (1) of the rotary cylinder, and tilted inward below the rotary cylinders (2a) and (2b). Although it is scattered in the scattering space (S) formed between the conveyor belts (7) and (7), these scattered substances are placed in the lower middle part of both cylinders and have a partition plate (4) of variable vertical length. ), The left and right materials fall without mixing, and at the point where the partition plate (4) is cut, some of the scattered materials of raw materials A and B are mixed at the boundary portion of the left and right scattered materials, As shown in FIG. 2, the multi-layered fleece (5) having the mixed layer C of the left and right materials A and B is taken out by the drawing roll (6).

[0008]

In the present invention, as described above, the boundary portion (C layer) between the A layer and the B layer of the multi-layer fleece is a portion where a part of the felt material scattered materials A and B having different compositions are mixed when scattered and dropped. Therefore, the fibers in the material are sufficiently entangled with each other, and the delamination strength after forming the felt original fabric by the post-processing is equal to or more than that of a single layer of felt bonded to form a multilayer. This cannot be realized by simply laminating the fleece and making it a felt by post-processing.

Further, it becomes possible to change the structure of the multilayer fleece obtained by adjusting the length of the partition plate between the rotating cylinders, that is, the descending height. For example, the fleece manufactured by removing the partition plate or lifting it to the upper end and fully opening it is in a state in which the felt materials A and B are mixed throughout. In this case, the physical properties after making the felt original fabric by the post-processing become the same as the post-processed felt of the fleece prepared by simultaneously introducing the felt materials A and B from the same conveyor.

Further, the structure of the fleece manufactured by lowering the partition plate as described above has a three-layer structure of A layer from felt material A, B layer from material B and C layer which is a mixed layer of materials A and B. Become. When the partition plate (4) is lowered further as shown in FIG. 3, the C layer becomes thin as shown in FIG. 4, and in this case, the physical properties at the time of the felt original fabric are almost the laminated product of the material A and the material B except the delamination strength. Is equivalent to

By thus adjusting the height of the partition plate, it becomes possible to easily manufacture a multilayer fleece for obtaining a felt raw fabric having a composition and physical properties in one step in any combination. Therefore, the great advantage of economically producing a multi-layered felt is obtained.

Further, as shown in FIG. 1, the conveyor belt (7) installed in the lower part of the rotary cylinder is provided with air permeability, and a suction duct (8) for sucking mixed and falling materials is provided on the back side of the conveyor belt (7). The falling directions of the A layer and the B layer, which are the surface of the obtained felt original fabric, can be adjusted more reliably.

Further, two or more rotary cylinders are installed in parallel, partition plates of variable length are respectively installed between these rotary cylinders, and the number of laminated layers and the properties of each layer are arbitrarily changed by changing the raw materials fed from each raw material supply conveyor. The increase and decrease can be adjusted.

The advantages of the two-layer felt example are: First, there are the following three types of felts manufactured conventionally.

(1) Cure felt: A material in which a thermosetting resin such as a phenol resin is mixed as a binder into fibers such as synthetic fibers and natural fibers to prepare a fleece, which is then formed into a mat in a heating furnace. (Ingredients may include fillers such as urethane foam.) (2) Molded felt: In place of or in combination with the thermosetting resin in the above-mentioned cure felt, a heat-fusible fiber or a thermoplastic resin is used to form a mat. Mold. This felt can be cold-formed by reheating. (3) Semi-cure felt: Molded into a mat shape by softening the heating conditions in the manufacturing conditions of the cure felt. Since this felt contains a large amount of uncured thermosetting resin in its components, hot press molding It will be possible.

Use examples and advantages of the two-layered felt in which two kinds of them are combined are listed.

Structure 1 (Cure Felt and Cure Felt) Since the cure felt produced for sound absorption needs to be soft, the density setting is low, so that when it is used on a floor or the like, a feeling of bottoming appears. It will be a disadvantage. On the contrary, when the cured felt is manufactured by increasing the density while avoiding the feeling of bottoming, the hardness increases and the sound absorbing effect decreases. Therefore, in a place where noise is generated from the floor surface like a car, a two-layered structure of a soft cured felt as the lower layer and a hard cured felt as the upper layer is excellent in sound absorption and vibration absorption and has no feeling of bottoming. Very effective as underfloor material. Further, since the density of the lower layer is reduced, there is an advantage in terms of material cost and a great advantage that the weight of the whole felt can be reduced. The difference in hardness between the upper and lower layers can be obtained by adjusting the amount of the mixed resin in addition to the difference in the density at the time of manufacturing the fleece, and the same can be obtained by adjusting the fibers used. In this way, the same effect can be obtained by adjusting the compounding composition including the filler. According to the present invention, such a structure can be easily obtained in one step. The same effect can be obtained with a combination of molding felts and a combination of semi-cure felts.

Structure 2 (Molded Felt and Cure Felt) A felt having a structure in which expensive felt is used in the upper layer and a cured felt is used in the lower layer is a felt in which all layers are made of expensive colored fibers. Compared with this, the material cost is low, which is very advantageous. The same effect can be obtained by arranging an inexpensive uncolored molded felt layer as the lower layer. Further, by disposing secure felt in the lower layer and performing heat molding, a molded article having a colored fiber layer on the surface layer and having excellent designability can be obtained. Also, for automobiles, in the structure where the molded felt layer is arranged in the lower layer and the cured felt is arranged in the upper layer, by fitting the molded felt to the unevenness of the floor of the automobile, the fit is improved and sound absorption and vibration absorption are improved. It can be dramatically increased, and the presence of the cured felt on the surface provides a great advantage of eliminating the feeling of bottoming, and is very effective as a material for underfloor products for automobiles. According to the present invention, such a configuration can be realized at low cost.

Structure 3 (Semi-Cure Felt and Cure Felt) A heat-molded product of a semi-cure felt is often used in a portion where heat resistance is required. However, since the molded product of the semi-cure felt has high density and hardness, it has a defect of poor sound absorption. Therefore, when hot molding is performed with a configuration in which a soft cure felt is placed on the surface of the semi-cure felt, the thermosetting resin in the component of the cure felt of the surface finishes curing when it is manufactured into a mat, so heating after that. In the molding, the hardness remains unchanged and the soft state is maintained, while the semi-cure felt is molded into a predetermined hardness and shape. Therefore, a cured felt having a high sound absorbing property is arranged on the surface layer to obtain a molded product excellent in moldability and heat resistance. These products are very useful as automobile parts. According to the present invention, such a configuration can be easily obtained. Further, this effect can be similarly obtained by using a molding felt having a small amount of binder component in the surface layer as a substitute for the cure felt.

[0020]

EXAMPLE By using the felt materials A and B shown in Table 1 by the apparatus of the present invention in FIG. 3, the surface density and the layer thickness of the felt raw fabric after post-processing are set to the values shown in the table, respectively. A felt fleece having a two-layer structure was obtained and post-processed to obtain a felt original fabric. The post-processing conditions are heating temperature of 160 ° C x 6 minutes,
The heating method was an iron plate sandwich heating method.

[0021]

[Table 1]

The physical properties of the obtained felt raw fabric were measured as shown in Table 2. In the table, the conventional product refers to a single-layer-bonded felt raw fabric consisting of the A-layer-only felt fabric and the B-layer-only felt fabric, and the comparative product is a simple overlay of each fleece of material A and material B. It is a combined original fabric product.

[0023]

[Table 2]

Table 2 shows that the product of the present invention has improved tensile strength and interlaminar peel strength as compared with the conventional product and the comparative product.

Further, according to the present invention, as shown in FIG. 5, three rotary cylinders (2a), (2b) and (2c) are arranged side by side,
Felt materials using raw material supply conveyors (3a) (3b) for the rotating cylinders (2a) (2b) on both sides and a raw material supply tower (9) for the central rotating cylinder (2c). A, B, C are supplied, and the partition plates (4a) (4
A device provided with b) is also obtained. The fleece obtained by this device is felt material A, B, C as shown in FIG.
A fleece (5) having a multi-layer structure of each layer, a mixed layer of A layer and C layer, a D layer, and a mixed layer of B layer and C layer, E layer is obtained.

[0026]

As described above, according to the present invention, a multi-layered felt composed of a plurality of layers having different properties and characteristics can be easily obtained at a low cost, and the bonding state between the layers is good, so that it can be used as a felt product. It has a remarkable effect such as widening the range.

[Brief description of drawings]

FIG. 1 is an explanatory view showing an embodiment of the device of the present invention.

FIG. 2 is a cross-sectional view showing a fleece having a two-layer structure obtained by the device of FIG.

FIG. 3 is an explanatory view showing an embodiment of the device of the present invention.

4 is a cross-sectional view showing a two-layer structure fleece obtained by the device of FIG.

FIG. 5 is an explanatory view showing another embodiment of the device of the present invention.

6 is a cross-sectional view showing a multi-layered fleece obtained with the device of FIG.

[Explanation of symbols]

 1 Scraper 2a, 2b, 2c Rotating cylinder 3a, 3b Raw material supply conveyor 4, 4a, 4b Partition plate 5 Fleece 6 Drawer roll 7 Conveyor belt 8 Suction duct 9 Raw material supply tower

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tadatoshi Higuchi 4-43-5 Higashi Yotsugi, Katsushika-ku, Tokyo Asahi Cork Industry Co., Ltd.

Claims (4)

[Claims] 1. The felt material is separately scattered into the felt material scattering space by using a plurality of rotating cylinders in which a scraping needle is planted on the circumferential side surface, and thereafter, the felt material scattering material is separated from the adjacent scattering material. A multi-layered fleece having a multi-layered structure in which the felt materials are mixed at the boundary portions by mixing the boundary portions and pushing the felt material scattered pieces from the lower part of the scattering space in the stacking direction Manufacturing method of felt fleece. 2. A plurality of rotating cylinders in which a scraping needle is planted on the circumferential side surface are arranged side by side in a lateral direction, and each of the rotating cylinders is provided with a supply means for supplying a felt material to the rotating cylinders. Conveyor belt surfaces that are inclined inward toward each other on both sides are provided, and a felt material scattering space is provided below the rotating cylinder group, and a downward length between the respective rotating cylinders is set in the felt material scattering space. A multi-layer felt fleece manufacturing device, which is equipped with a partition plate that can be freely bent. 3. The apparatus for manufacturing a multi-layer felt fleece according to claim 2, wherein two rotary cylinders are arranged side by side, and a partition plate which is vertically movable is provided between them. 4. The conveyor belt surface is breathable, and a suction duct is provided on the back surface side of the conveyor belt surface.
Or the manufacturing apparatus of the multilayer felt fleece according to 3.