TWI429415B - Production method of cleaning sheet body, cleaning sheet body, lumpy fiber aggregate bundle and lumpy fiber aggregate bundle - Google Patents

Description

Cleaning sheet, method for producing sheet for cleaning, bulk fiber bundle, and method for producing bulk fiber bundle

The present invention relates to a sheet for cleaning which is particularly suitable for cleaning a hard surface or the like.

Various bundles of fibers in the shape of a sphere are known at present. For example, Patent Document 1 describes a wadding in which a wool fiber is included and a wool fiber of an outer layer is felted. The spherical wadding is produced by cutting a fiber strip of the opened fiber into a predetermined length to form a fiber sheet, sandwiching the fiber sheet between the opposite sides, and by moving the fiber The fiber sheet is rubbed by the two or the other, and the fiber sheet is made into a spherical shape, and the outer layer portion of the fiber sheet is humidified, and the outer layer portion of the spherical fiber sheet is fluffed and felted.

Patent Document 2 describes a cotton wadding for use in bedding or winter clothes. The cotton wadding is produced by blowing a pearl cotton containing a main fiber and an adhesive fiber having a softening point lower than the fiber by 20 ° C or more into a quilt, and then heat-treating and integrating the same.

Patent Document 3 describes a spherical fiber structure including a wet heat-bonding staple fiber and a thermoplastic crimp staple fiber. A part of the fibers constituting the spherical fiber structure is thermally bonded by wet heat and subsequent crimping of the staple fibers. The globular fiber structure is produced by spreading a hybrid staple fiber containing a wet heat-bonded staple fiber and a thermoplastic crimped staple fiber onto a wire mesh, and spraying the water while spraying the metal. After rolling and rotating on the screen, the granules are impregnated in water, and then bubbles are generated in the water-containing granules by boiling, so that a large number of cell-shaped void portions are formed inside the granules. At the same time, a portion of the fibers constituting the granules are thermally heated by the use of the moist heat entangled staple fibers.

In each of the above documents, there is no mention of a material in which the bundle of spherical fibers described in these documents can be used as a sheet for cleaning.

Unlike the spheroid, the sheet for cleaning having a fiber assembly is known, for example, as described in Patent Document 4. The cleaning sheet according to this document includes a heat-soluble sheet and a plurality of long-melting long fibers which are joined to the sheet and extend in one direction. The long fibers extend in a direction intersecting therewith, and are joined to the heat-soluble sheet by a plurality of root-solving lines intermittently disposed along the longitudinal direction of the long fibers. When the cleaning sheet system captures dirt between the long fibers, since the long fibers are fixed by the dissolution line before and after, the degree of freedom of movement is restricted, and the dirt is reliably captured between the fibers. Not enough. Moreover, since the portion of the dissolution line does not trap dirt, the efficiency of capturing the dirt is not sufficient.

Patent Document 5 describes a cleaning sheet similar to the cleaning sheet described in Patent Document 4. The cleaning sheet system described in this document combines a fiber bundle body in which a plurality of fibers are bundled with a base sheet body to constitute a cleaning portion. According to the document, the cleaning sheet can be sufficiently wiped off even for a certain amount of large dirt. However, since the fibers in the cleaning sheet are aligned in one direction, there is a case where the dirt cannot be reliably caught due to the wiping direction.

Patent Document 1: JP58-70758A

Patent Document 2: JP61-125377A

Patent Document 3: JP2002-212868A

Patent Document 4: US 6,329,308 B1

Patent Document 5: JP2007-289341A

The present invention provides a cleaning sheet which is formed by bonding a plurality of bundled fiber bundles on at least one surface of a substrate sheet to form a cleaning portion which is bounded in one direction by a joint portion. The plurality of aligned fibers are joined to each other, and the fibers extending from the joint are in an open state.

Moreover, the present invention provides a method for producing a sheet for cleaning, which is a preferred method for producing the sheet for cleaning, and the method for producing the sheet is:

The plurality of continuous filaments arranged in one direction are joined to each other by a plurality of joints extending in a direction crossing the extending direction of the fibers to form a continuous long fiber bundle.

Cutting the continuous long fiber bundle between the joint portions to obtain an unfiber-opened short fiber bundle,

Spraying a fluid onto the unfiber-opened staple fiber bundle to open fibers extending from the joint portion to obtain a bundle of bulk fibers,

A plurality of the above-mentioned bundles of bulk fibers are joined to at least one side of the substrate sheet.

Moreover, the present invention provides a method for producing a sheet for cleaning, which is another preferred method for producing the sheet for cleaning, the method of which is:

The plurality of continuous filaments arranged in one direction are joined to each other by a plurality of joints extending in a direction crossing the extending direction of the fibers to form a continuous long fiber bundle.

Cutting the continuous long fiber bundle between the joint portions to obtain an unfiber-opened short fiber bundle,

Joining a plurality of the unfiber-opened staple fiber bundles on at least one side of the substrate sheet,

The fluid is sprayed onto the unfiber-opened staple fiber bundle, and the fiber extending from the joint portion is opened to obtain a bundle of bulk fibers that are fixed to the substrate sheet.

Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings. Fig. 1 is a perspective view showing a first embodiment of the cleaning sheet of the present invention. Figure 2 is a cross-sectional view taken along line II-II of Figure 1. The cleaning sheet 10 of the present embodiment includes a substrate sheet body 11. The base sheet 11 has a rectangular shape in the longitudinal direction X and a width direction Y orthogonal thereto. The cleaning sheet 10 has a cleaning portion 12 on one surface of the substrate sheet. The cleaning unit 12 has a substantially rectangular shape having a longitudinal direction X and a width direction Y in plan view. The cleaning portion 12 is located in a central region of the substrate sheet 11 in the width direction Y. The substrate sheet 11 extends laterally from the left and right side edges 12a of the cleaning portion 12 to form a pair of wing portions 11a. On the other hand, in the longitudinal direction X, the cleaning portion 12 extends over the entire region X in the longitudinal direction of the substrate sheet 11. The cleaning unit 12 includes a fiber assembly and is formed to have a predetermined thickness.

The fiber assembly constituting the cleaning unit 12 includes a bundle of fibers in a block shape (for example, a spheroidal to a genus-like type). Hereinafter, the block fiber bundle will be described. The bundle of bundled fibers is produced from the unfiber-opened staple fiber bundle 20' shown in Fig. 3. The unfiber-opened staple fiber bundle 20' is formed by joining a plurality of fibers 21 arranged in one direction by joining portions 22 extending in a direction crossing the extending direction of the fibers 21. Only one joint portion 22 is formed. The fibers 21 extending from the joint portion 22 of the unfiber-opened staple fiber bundle 20' are opened and formed into a block shape (for example, a spheroidal to a genus-like type), and are the bundles 20 of the block fibers shown in the same figure. The method of opening the fiber 21 will be described below.

The unfiber-opened staple fiber bundle 20' shown in Fig. 3 is flat, but the shape of the unfiber-opened staple fiber bundle 20' is not limited thereto, and may be, for example, a columnar shape or a square column shape or a twisted shape (spiral shape).

In the bulk fiber bundle 20 shown in Fig. 3, a joint portion 22 (not shown) is present in a substantially central region. Further, the fibers 21 extending from the joint portion 22 (not shown) are radially opened to form a block-shaped (for example, spherical to celotype-like) bulk fiber bundle 20 .

The fiber length of the fibers 21 constituting the bundle of the bulk fibers 20 is preferably from 3 to 150 mm, more preferably from 5 to 50 mm. By setting the fiber length within this range, the fiber 21 can be made to have a good fiber opening state, and it becomes possible to surely trap dirt between the fibers. When the fiber 21 has a crimp as described below, the length in the state in which the crimp is straightened is set to the length of the fiber 21.

The joint portion 22 is formed in a substantially central region in the longitudinal direction of the fibers 21 constituting the block-shaped fiber bundle 20. The joint portion 22 is formed by, for example, melting and solidification of the fibers 21. Alternatively, it is formed by using an adhesive. The joint portion 22 has a predetermined width d and extends in a direction orthogonal to the direction of the alignment of the constituent fibers 21 aligned in one direction. The width d of the joint portion 22 depends on the length or material of the fiber 21 and the means for forming the joint portion 22. However, if it is 0.5 to 80 mm, particularly 1 to 40 mm, the fibers 21 can be surely joined to each other.

The number of the fibers 21 contained in the bundle of the bulk fibers 20 depends on the thickness of the fibers 21, but is preferably from 100 to 100,000, more preferably from 1,000 to 50,000. By setting the number of the fibers 21 within this range, the fiber density in the fiber-opening state can be made to a value suitable for capturing dirt. For the same reason, the total fineness of the entire bulk fiber bundle 20 is preferably from 1 to 8000 tex, preferably from 10 to 4000 tex.

The thickness of the fiber 21 is preferably from 0.05 to 80 dtex, preferably from 0.5 to 40 dtex. By setting the thickness to be within this range, the fiber 21 can have an appropriate rigidity, and the cleaning portion 12 can sufficiently follow the cleaning target surface having the unevenness, for example, a sill or a sliding door. Further, the cleaning unit 12 can sufficiently follow a narrow place such as a corner of the room and the door stop and its surroundings. In turn, the dirt is captured.

As the fiber 21, it is preferable to use a crimper, which further improves the trapping property of the dirt. As the crimped fiber, a two-dimensional crimp or a three-dimensional crimp can be used. The crimping ratio of the crimped fiber (JIS L0208) is preferably from 5 to 50%, preferably from 10 to 30%. The crimp ratio is defined as the percentage of the difference between the length A of the drawn fiber and the original length B of the fiber relative to the length A of the drawn fiber, which can be calculated according to the following formula.

Crimping rate = (A-B) / A × 100 (%)

The number of crimps of the crimped fibers and the height of the projections are related to the bulk of the bundle of bundled fibers 20. In detail, the larger the number of crimps, the higher the height of the projections, and the bundle of bundled fibers 20 becomes bulky. In this regard, the number of crimps is preferably from 3 to 80, preferably from 5 to 40. The height of the protrusion is preferably 0.1 to 8.0 mm, preferably 0.2 to 4.0 mm.

The above number of crimps was measured in accordance with JIS L1015. The crimp height was measured in the following manner. The fiber 21 was observed, and the portion where the crimping of the three or more adjacent portions was the strongest (high) was found. A collection portion of the fibers 21 which are substantially bent into the same shape (not one fiber) is found everywhere, and the shape of the assembly portion is cut out without being deformed. The cut fiber 21 is fixed to either end side in the longitudinal direction thereof by a transparent tape so as not to be deformed without applying a load other than its own weight and thick paper or the like. In the case where the fiber 21 has a two-dimensional or three-dimensional crimp, the fixing is performed in such a manner that the difference between the projections and the depressions of the fibers 21 is maximized. The fiber 21 was photographed in such a manner that it was not raised from thick paper or the like and was as close as possible to a straight line. At this time, the actual size can be confirmed, and the scale and the like are also included in the same photo. A device that can be magnified by using a photocopier, a scanner, or the like, magnifies the obtained photograph (preferably 4 times or more) in such a manner that the fiber 21 can be clearly seen. Next, from the enlarged fiber 21, a crimping rule is selected and is a linear portion. Further, the upper and lower sides are determined by the fact that the fibers 21 are less unkempt or can be photographed more clearly. Note the inside and outside of the assembly of the fibers 21 and connect the vertices between adjacent depressions. Next, the distance between five consecutive projections to the line connecting the adjacent depressions and depressions is measured substantially vertically. Attention is paid to the magnification, etc., and five projections are measured to determine the actual size. The average value was taken as the measured value of this sample. The remainder cut out from the same sample was also measured in the same manner. The average value of the three of the larger samples was averaged and the average value was taken as the crimp height of the sample.

The size of the bundle of bundled fibers 20 (the size before being joined to the substrate sheet 11) is preferably 0.2 to 1000 cm ³ , preferably 0.5 to 125 cm ³ in terms of volume.

In the cleaning sheet 10, the block-shaped fiber bundles 20 are placed on one surface of the substrate sheet 11 without any gap, and joined to the substrate sheet 11, whereby the cleaning portion 12 is formed. Therefore, even if the shape of the bulk fiber bundle 20 is, for example, a spherical shape before joining, the bulk fiber bundle 20 can be made flat with a certain thickness by being joined to the base sheet 11. This thickness corresponds to the thickness of the cleaning portion 12. The bulk fiber assembly bundle 20 may be disposed in a single layer or in a multilayer configuration in two or more stages. In either case, the bulk fiber bundle 20 can be disposed at any portion of the cleaning portion 12 so as to have a substantially constant thickness.

As shown in FIG. 1, the base sheet body 11 and the block-shaped fiber assembly bundle 20 are joined at the joint point 13. The joint is formed by, for example, welding of the constituent sheets 21 of the base sheet 11 and the bulk fiber bundle 20. Alternatively, it is formed by the substrate sheet 11 and the fiber 21 subsequently. The joint 13 can be configured regularly or disregarded. The joint 13 can be regularly arranged according to the following manufacturing method.

The bulk fiber bundle 20 does not need to be joined to the substrate sheet 11 at the position of the joint portion 22. In other words, it is not necessary to form the joint 13 at the position of the joint portion 22. The bulk fiber bundle 20 can be placed at any position of the bulk fiber bundle 20 as long as the bulk fiber bundle 20 is joined to the substrate sheet 11 without being detached from the substrate sheet 11. The sheet bodies 11 are joined.

The total basis weight of the bulk fiber bundles 20 constituting the cleaning unit 12 depends on the total fineness of the bulk fiber bundles 20 or the length of the fibers 21, but the cleaning sheet 10 can be satisfactorily cleaned up with the unevenness. aspects target surface, and to impart a sense of volume of the cleaning sheet 10 so that the wiping feeling becomes good in terms of the aspect, preferably 10 ~ 1000g / m ^2, it is preferably 50 ~ 500g / m ^2. In association with this, the thickness of the cleaning sheet 10 of the cleaning portion 12 is preferably from 1 to 100 mm, preferably from 2 to 50 mm, under a load of 300 Pa.

In the cleaning portion 12, the fibers 21 constituting the bulk fiber bundle 20 are mainly oriented in the planar direction of the cleaning portion 12. The fibers 21 facing in the planar direction are not all oriented in the same direction, but in all directions in the plane. Further, in the fiber 21, a large amount of the fiber 21 is directed toward the thickness direction of the cleaning portion 12. Further, since one end of the fiber 21 has a free end, the degree of freedom of movement is extremely high. As described above, in the cleaning portion 12, since the fibers 21 are oriented in various directions and the degree of freedom of movement is extremely high, the dirt can be caught between the fibers 21 regardless of the direction in which the cleaning sheet 10 is wiped. On the other hand, for example, in the cleaning sheet described in Patent Documents 4 and 5 described in the prior art, since all the fiber systems are aligned in one direction, they can be rubbed in a direction crossing the direction thereof. In the case of the net, the dirt is trapped between the fibers, but when it is wiped in the direction thereof, the capturing efficiency of the dirt is remarkably lowered. Further, in the cleaning sheet described in Patent Document 4, since both ends of the fiber are fixed ends, the degree of freedom of movement of the fibers is low, and it is difficult to improve the efficiency of capturing dirt.

As the fiber 21, for example, a synthetic fiber containing a thermoplastic resin, a natural fiber such as cotton or hemp, a regenerated fiber such as rayon, or a semisynthetic fiber such as acetate can be used. These fibers may be used singly or in combination of two or more. The fiber 21 is preferably used as the fiber 21 in consideration of the ease of formation of the joint portion 22 of the unfiber-opened staple fiber bundle 20' (see Fig. 3) or the ease of bonding of the bulk fiber bundle 20 to the substrate sheet 11. A synthetic fiber comprising a thermoplastic resin which is a material which can be easily thermally welded. As the thermoplastic resin, a polyolefin resin such as polyethylene or polypropylene, a polyester resin such as polyethylene terephthalate, an acrylic resin, or a vinyl resin can be used. The synthetic fiber may be composed of a single resin or a composite fiber in which two or more kinds of resins are combined (for example, a core-sheath type composite fiber or a side-by-side type composite fiber).

Chemical agents may also be applied to the fibers 21. By applying a chemical agent for the purpose of dry dry cleaning, the trapping property by adsorbing dirt can be improved. As such a chemical agent, various oil agent components are mentioned. As the oil component, for example, an oil agent such as mineral oil, synthetic oil or polyoxygenated oil may be used, and a surfactant, a solvent, an antioxidant, a fragrance or the like may be mixed with the oil component. The coating amount of the chemical agent including the oil component may be about 0.1 to 50% by weight based on the weight of the fiber 21.

In the case where the cleaning sheet 10 of the present embodiment is used for the purpose of wet-wet cleaning, the cleaning agent can be impregnated by the impregnation of the cleaning agent, thereby improving the cleaning property. As the cleaning agent, a surfactant, a solvent, a disinfectant, a preservative, a fragrance, water, or the like can be used. The impregnation amount of the cleaning agent can be set to about 20 to 500% by weight based on the weight of the fiber 21.

The cleaning sheet 10 of the present embodiment can be used for the purpose of dry dry cleaning and wet wet cleaning, and can also be used for wiping, wiping, and impregnating liquids such as water, commercially available cleaning agents, and waxes. Such as the use of rags.

As the substrate sheet 11 of the fixed bulk fiber bundle 20, in terms of ease of bonding with the bulk fiber bundle 20, for example, various nonwoven fabrics or films containing synthetic resin, paperboard containing pulp, and the like can be used. Paperboard made of synthetic resin mixed with pulp, or a composite material of these. In the case of using a non-woven fabric, for example, a hot air non-woven fabric, a spunbonded non-woven fabric, an air-laid non-woven fabric, or the like can be preferably cited. In terms of strength or other aspects of the viscosity, the basis weight of such non-woven fabric is preferably 3 ~ 200g / m ^2, is preferably 10 ~ 100g / m ^2. For the same reason, in the case of using a film, the basis weight is preferably from 3 to 500 g/m ² , preferably from 10 to 250 g/m ² . In the case of using paperboard, the basis weight is preferably from 10 to 500 g/m ² , preferably from 20 to 250 g/m ² . The synthetic resin constituting the substrate sheet 11 can be the same as the synthetic resin constituting the fiber 21 described above.

The cleaning sheet 10 can be used, for example, as shown in FIG. 4, and attached to the cleaning tool 100. The cleaning tool 100 includes a head portion 101 to which the cleaning sheet body 10 can be attached, and a rod-shaped handle 102 connected to the head portion 101 via the universal joint 103. The mounting surface (bottom surface) of the head portion 101 has a rectangular shape in plan view. In a normal use state, the cleaning tool 100 moves the head portion 101 in the width direction (particularly, reciprocating movement) to perform cleaning. The cleaning sheet 10 is attached to the head 101 of the cleaning tool 100 including the head portion 101 and the handle 102 attached to the head portion 101 by the base sheet body 11. The cleaning sheet 10 is attached to the head portion 101 such that the side of the base sheet 11 on which the cleaning portion 12 is not provided faces the mounting surface (bottom surface) of the head portion 101. Next, the wing portion 11a of the substrate sheet 11 is folded back to the upper side of the head portion 101. Further, the wing portion 11a is inserted into a plurality of sheet holding portions 104 having flexibility of the radial slits on the head portion 101. As described above, the cleaning sheet 10 can be fixed to the head 101 of the cleaning tool 100 by the wing portion 11a of the substrate sheet 11. In the case where the substrate sheet 11 contains a mesh (sparse yarn) as in the embodiment shown in FIG. 11 and FIG. 12 described below, the bonding force between the substrate sheet 11 and the sheet holding portion 104 is Improve, so it is better. In this state, the cleaning sheet 10 of the present embodiment can be used, for example, for wiping a hard surface such as a floor, a wall, a ceiling, a glass, a mirror or a furniture, a home appliance, a house exterior wall, or a car body.

Next, a preferred method of manufacturing the cleaning sheet 10 of the present embodiment will be described with reference to Figs. 5 to 9 . The manufacturing method can be roughly classified into: (a) a manufacturing step of the bulk fiber assembly bundle 20, and (b) a bonding step of the bulk fiber assembly bundle 20 and the substrate sheet 11. (A) The manufacturing steps of the bulk fiber bundle 20 can be roughly classified into: (A-1) manufacturing steps of continuous long fiber bundles, (A-2) manufacturing steps of unfiber-opened short fiber bundles, (A-3) The manufacturing steps of the bundle of bundled fibers.

The manufacturing process of the continuous long fiber bundle of (A-1) is a process of forming a plurality of continuous long fibers arranged in one direction by joining a plurality of joint portions extending in a direction crossing the extending direction of the fibers. Continuous long fiber bundles. The manufacturing step of the unfiber-opened staple fiber bundle of (A-2) is to cut the continuous long fiber bundle between the joint portions to obtain an unfiber-opened short fiber bundle. The manufacturing step of the bundle of the block fibers of (A-3) is to spray a fluid onto the unfiber-opened short fiber bundle, and to open the fibers extending from the joint portion to obtain a bundle of bulk fibers.

First, a manufacturing step of facing the (A) block-shaped fiber bundle 20 will be described with reference to Figs. 5 to 8 . Fig. 5 is a view showing a manufacturing apparatus 30 for a continuous long fiber bundle and an unfiber-opened short fiber bundle. First, the bundle 23 of continuous filaments as a raw material is taken out from the supply unit 31. The bundle of continuous long fibers 23 is a bundle of a plurality of continuous long fibers that are aligned in one direction. The continuous filaments are the constituent fibers 21 of the target bulk fiber bundles 20. The number of continuous long fibers in the bundle of continuous long fibers 23 may be equal to the number of fibers 21 in the target bulk fiber bundle 20, or may be more than the number of fibers 21 in the target bulk bundle 20 .

The bundle of continuous long fibers 23 that has been taken out is introduced into the fiber opening device 32, and is widened in a direction orthogonal to the conveying direction, thereby producing the opened fiber bundle 24. This state is shown in Fig. 6 (a). Further, in Fig. 6(a), the direction from the left side to the right side of the paper surface is the conveying direction. The same is true in Figs. 6(b) to (d). The fiber opening device 32 includes a pair of block rolls 33 and 34 which are provided in a plurality of pairs (three pairs in Fig. 5) in the conveying direction of the bundle 23 of continuous long fibers. The pair of block rolls 33 and 34 include a plurality of grooved grooves 33 extending in the circumferential direction and a metal grooved roll 33 which are alternately arranged in the axial direction, and a circumferential contact with the grooved roll 33 and a circumferential surface An anvil roll 34 formed of rubber. The block rolls 33, 34 thus constructed are well known in the art. The bundle of continuous long fibers 23 is increased in width by passing between the grooved roll 33 and the anvil roll 34, thereby producing an open fiber bundle 24.

The opened tow 24 obtained by the fiber opening device 32 is introduced into the chemical coating device 35. In the chemical coating device, a chemical agent is applied from above and below the opened filament bundle 24. As the chemical agent, those described above are used. When applying a chemical, for example, a spray device can be used. Further, an embossing roll coating method can also be used when applying a chemical.

The open fiber bundle 24 coated with the chemical is then introduced into the joining device 36. The joining device 36 is provided with a pair of embossing rolls 36a and 36b. Each of the embossing rolls 36a and 36b includes linear ridges 36c extending in the axial direction thereof, and is arranged at a predetermined interval along the circumferential direction. Each of the embossing rolls 36a and 36b can be heated. In the rotated state, the ribs 36c of one embossing roll 36a are in opposed contact with the ribs 36c of the other embossing roll 36b. When the opened tow 24 passes between the two rolls, the continuous long fibers constituting the opened tow 24 are melt-solidified by the action of heat and pressure, and the opened tow 24 is formed with continuous filaments constituting the same. A plurality of joint portions 22' extending in a direction in which the direction of intersection extends. This state is shown in Fig. 6(b). As shown in FIG. 6(b), the joint portion 22' extends in a direction orthogonal to the extending direction of the continuous long fibers constituting the open fiber bundle 24. In FIG. 6(b), the joint portion 22' is represented by a straight line extending in a direction orthogonal to the extending direction of the continuous long fibers constituting the open fiber bundle 24, and may also extend in the oblique direction. Instead of a straight line or a curve. The distance between the joint portions 22' is fixed. The continuous filaments are joined to each other by the formation of the joint portion 22'. The joint portion 22' corresponds to the joint portion 22 of the unfiber-opened staple fiber bundle shown in Fig. 2 described above.

The open fiber bundle 24 in which a plurality of joint portions 22' are formed is introduced into the slitter 37. The slitter 37 includes a first roller 37a and an anvil roller 37b in which a plurality of circular blades are arranged at predetermined intervals in the axial direction of the roller. By introducing the opened filament bundle 24 into the slitter 37, the opened filament bundle 24 can be cut at a predetermined interval in the extending direction of the continuous long fibers and in the width direction. As a result, as shown in FIG. 6(c), a plurality of continuous long fiber bundles 25 formed by cutting the opened tow 24 in the width direction are formed.

Each of the continuous long fiber bundles 25 is introduced into the width direction cutting device 38 as shown in FIG. The width direction cutting device 38 includes a first roller 38a that is disposed at a predetermined interval in the circumferential direction, and an anvil roller that is disposed opposite to the first roller 38a. 38b. The two rolls 38a and 38b are disposed such that the ridge bar 38c of the first roll 38a is in contact with the circumferential surface of the anvil roll 38b or in a distance relationship close to the circumferential surface. By introducing the continuous long fiber bundle 25 between the two rolls of the width direction cutting device 38, as shown in Fig. 6(d), the position between the joint portions 22' (the position indicated by a broken line in the figure) The continuous long fiber bundle 25 is cut along the width direction. The target unfiber-opened staple fiber bundle 20' can be obtained by the cutting.

In the above, in the step of producing the unfiber-opened staple fiber bundle 20' from the bundle 23 of continuous long fibers as a raw material, the unfiber-opened staple fiber bundle 20' may be produced in another order. The manufacturing method will be described with reference to FIGS. 7(a) and 7(b). In the present production method, the step of forming the opened fiber bundle 24 from the bundle 23 of the continuous long fibers as the raw material and applying the oil agent thereto is the same as the production method shown in Figs. 5 and 6 . The open fiber bundle 24 coated with the oil agent is introduced into the dividing device 39, and is divided into a plurality of pieces at a predetermined interval in the extending direction of the continuous long fibers and in the width direction to become a plurality of divided open fiber bundles. 26. The state is shown in Fig. 7(b). The dividing device 39 includes a pair of block rolls 39a and 39b which are provided in a plurality of pairs (three pairs in Fig. 7(a)) along the conveying direction of the opened fiber bundle 24. The pair of block rolls 39a and 39b include a metal grooved roll 39a in which a plurality of grooves and ridge portions extending in the circumferential direction are alternately arranged in the axial direction, and a circumferential contact with the grooved roll 39a. An anvil roll 39b formed of rubber. The arrangement of the grooves of the grooved rolls 39a is such that the open fiber bundles 24 are divided into a plurality of positions in the width direction thereof. The number of continuous long fibers of each divided open fiber bundle 26 obtained by the dividing device 39 is the same as the number of fibers 21 of the target unfiber-opened short fiber bundle 20'.

Each divided open fiber bundle 26 is then introduced into the engagement device 36. This joining device 36 is the same as that shown in FIG. The continuous long fibers constituting the divided split bundle 26 are melt-solidified by the action of heat and pressure of the joining device 36, and an extension along the continuous filaments constituting the split filament bundle 26 is formed on the split open strand 26 A plurality of joint portions 22' extending in a direction in which the directions intersect. This state is the same as the state shown in Fig. 6(c). Thereby, a plurality of continuous long fiber bundles 25 can be formed. The continuous long fiber bundle 25 is introduced into the width direction cutting device 38. This width direction cutting device 38 is the same as that shown in FIG. The continuous long fiber bundle 25 is cut along the width direction at a position between the joint portions 22' by the width direction cutting device 38. This state is the same as the state shown in Fig. 6(d). The target unfiber-opened staple fiber bundle 20' can be obtained by the cutting.

The unfiber-opened staple fiber bundle 20' manufactured using the apparatus shown in Fig. 5 or the apparatus shown in Fig. 7 is supplied to the fiber opening step. Referring to Figures 8(a) and (b), the details of the fiber opening step will be described. As shown in Fig. 8(a), the unfiber-opened staple fiber bundle 20' is introduced into the hollow chamber 40 in an airtight state. The chamber 40 is provided with an introduction portion 41 for introducing a fluid into the chamber 40, and a discharge portion 42 for discharging the fluid introduced into the chamber 40 to the outside.

When the fluid is introduced into the chamber 40 through the introduction portion 41, the introduced fluid forms a turbulent flow in the chamber 40. This turbulent flow will disturb the unfibered staple fiber bundle 20'. As a result, as shown in FIG. 8(b), the fiber 21 extending from the joint portion 22 of the unfiber-opened staple fiber bundle 20' is opened, and is expanded substantially radially around the joint portion 22. As described above, the target bulk fiber bundle 20 can be obtained.

Examples of the fluid used in the fiber opening include a gas and a liquid. As the gas, it is advantageous to use air from the viewpoint of economy or operability, and it is also possible to use a gas other than the gas, for example, nitrogen. Gases that are flammable or explosive are not easy to handle. As the liquid, it is preferred to use a higher volatility. As a fluid, it is advantageous to use water from the viewpoint of economy or operability.

When a gas such as a gas is used as the fluid, a gas is introduced into the chamber 40 from the introduction portion 41 by means of a compressor that applies energy (pressure) to the gas, a blower that blows the gas, and the like, and the discharge portion 42 is introduced. The gas is discharged to the outside, thereby generating a turbulent flow of gas in the chamber 40. The amount of air to be ejected and the discharge pressure of the bulk fiber bundle 20 for obtaining the target are based on the number of crimps of the fibers constituting the unfiber-opened staple fiber bundle 20', the height of the projections, the number of fibers, the length of the fibers, the thickness of the fibers, Or the amount of the unfiber-opened short fiber bundles 20' and the volume of the chamber are different in the chamber 40, but the former is preferably set to 0.5 to 100 m ³ /min, and the latter is preferably set. It is 0.1~1.0MPa.

Instead of using the fiber opening method of the apparatus shown in Fig. 8, it is also possible to use a fiber opening method such as a card. Alternatively, a stirring method using a device for pulverizing wood pulp, that is, a stirring rotor, is employed.

Then, the step of fixing the obtained bulk fiber bundle 20 and the substrate sheet 11 is carried out, that is, the above step (b). This step will be described with reference to FIG. In the manufacturing apparatus 50 shown in Fig. 9, first, the entire sheet 11' is taken out from the entire sheet roll 11a of the substrate sheet 11. A bulk fiber bundle 20 is disposed on one surface of the entire sheet 11' to be drawn. This configuration uses a suction device 51. The suction device 51 is provided with a suction pipe 52. One end of the suction pipe 52 is located in the housing box 53 in which the plurality of block-shaped fiber bundles 20 are housed. The other end of the suction pipe 52 is opposed to one face of the entire sheet body 11', from which the surface is located at a predetermined interval. The other end of the suction pipe 52 has a horizontally wide opening portion 52' extending in the width direction of the entire sheet body 11'.

The suction device 51 is activated, and the bulk fiber bundle 20 housed in the storage box 53 is sucked together with the air. By the suction, the bundle fiber bundle 20 is sucked into the tube 52 from one end of the suction tube 52, and is sent into the suction tube 52. Then, it is discharged through the other end of the tube 52, that is, the opening portion 52', and placed on the entire sheet body 11'. The bulk fiber bundles 20 are randomly arranged. By adjusting the degree of suction or the shape of the opening portion 52', the bulk fiber bundle 20 can be spread over the entire sheet 11' without any gap.

The entire sheet 11' on which the bundled fiber bundles 20 are placed is introduced into the embossing device 54. The embossing device 54 includes a first roller 54a in which a plurality of projections 54c are disposed on the circumferential surface, and an anvil roller 54b disposed to face the first roller 54a. The two rollers 54a and 54b are disposed such that the projections 54c of the first roller 54a are in contact with the circumferential surface of the anvil roller 54b or in a distance relationship close to the circumferential surface. Of the two rolls 54a and 54b, at least the first roll 54a is heated. In addition to the embossing device 54 as described above, a method may be employed in which a roller similar to the projection 54c of the first roller 54a is disposed instead of the roller of the anvil roller 54b disposed opposite the roller 54a, and the projections 54c are brought into contact with each other. Pattern method (Tip to Tip method). The fibers 21 and the entire sheet 11' constituting the bulk fiber bundle 20 are melt-solidified by the action of heat and pressure of the embossing device 54, and the bulk fiber bundle 20 and the entire sheet 11 are formed. 'Joining. By this bonding, a plurality of joints 13 can be formed (see Fig. 1). As described above, since the bulk fiber bundles 20 are disposed on the entire sheet body 11' without being ignored, the joints 13 are formed at arbitrary positions on the bulk fiber bundle 20. Further, the present invention is not limited to the case where one joint 13 is formed on one bulk fiber bundle 20, and two or more joints 13 are formed on one bulk fiber bundle 20. The shape of the joint 13 is roughly shown as a dot (circular) shape, and may be replaced by a shape other than an elliptical shape, a triangular shape, a square shape, a V shape, or a cross shape such as a cross shape. Further, in order to increase the bonding strength between the bulk fiber bundle 20 and the entire sheet 11', a bonding wire such as a straight line, a diagonal line, or a curved line may be used, or these may be used in combination.

The bulky bundle 20 of the heat and pressure imparted by the embossing device 54 has a reduced bulkiness. Therefore, the fluid is ejected from the bulk fiber bundle 20 joined to the entire sheet body 11' by the fluid ejecting device 55 disposed on the downstream side of the embossing device 54. By ejecting the fluid, the constituent fibers 21 of the bulk fiber bundle 20 can be disturbed to be opened, thereby restoring the bulk of the bulk fiber bundle 20. As the fluid for spraying, the same fluid as that used in the opening step of the unfiber-opened staple fiber bundle 20' shown in Fig. 8 can be used. The preferred fluid is air. In the case where air is used as the fluid, the degree of ejection is based on the number of crimps, the height of the projections, the number of fibers, the length of the fibers, and the thickness of the fibers constituting the bundle of bundled fibers 20 joined to the entire sheet 11'. The degree of the joint and the embossing pattern is different, and the amount of the jetted air for obtaining the target opening state is preferably 0.5 to 100 m ³ /min, and the discharge pressure is preferably 0.1 to 1.0 MPa. In addition to the fluid ejecting method for recovering the bulkiness of the bulk fiber bundle 20, a step of carding or rubbing at a protrusion such as a brush or a comb may be employed. Also, these may be combined.

Thus, the long-length cleaning sheet 10' can be obtained. The sheet 10' is introduced into the width direction cutting device 56. The width direction cutting device 56 includes a first roller 56a that is disposed at a predetermined interval in the circumferential direction, and an anvil roller 56b that is disposed to face the first roller 56a. The two rolls 56a and 56b are arranged such that the ridge bar 56c of the first roll 56a is in contact with the circumferential surface of the anvil roll 56b or in a distance relationship close to the circumferential surface. By introducing the sheet body 10' into the width direction cutting device 56, the sheet body 10' can be cut at a predetermined interval along the width direction. By this cutting, the sheet 10' can be made into a single piece, and the target cleaning sheet 10 can be obtained.

Further, in the present manufacturing method, the chemical application device 35 described above with reference to FIGS. 5 and 7 may be provided at an adjacent downstream position of the embossing device 54 shown in FIG.

Fig. 10 shows a manufacturing method different from the manufacturing method shown in Fig. 9. This manufacturing method uses the same apparatus 50 as the manufacturing method shown in FIG. The manufacturing method differs from the manufacturing method shown in Fig. 9 in the raw materials used. In detail, the manufacturing method does not join the bulk fiber bundle 20 with the entire sheet 11' of the substrate sheet 11, but the entire width of the unfiber-opened staple fiber bundle 20' and the substrate sheet 11. The sheets 11' are joined. The specific operation is as follows. Further, the description about the manufacturing method shown in Fig. 9 can be appropriately applied to the place where it is not particularly described.

First, the entire sheet 11' is taken out from the entire sheet roll 11a of the substrate sheet 11. Using the suction device 51, the unfiber-opened staple fiber bundle 20' is placed on one surface of the drawn sheet body 11'. The unfiber-opened staple fiber bundles 20' are randomly arranged. Unlike the method shown in Fig. 9 in which the bulk fiber bundle 20 is disposed, the present manufacturing method does not need to spread the unfiber-opened staple fiber bundle 20' without a gap.

The entire sheet 11' on which the unfiber-opened staple fiber bundle 20' is placed is introduced into the embossing device 54. By using the heat and pressure of the embossing device 54, the fibers 21 and the entire sheet 11' constituting the unfiber-opened staple fiber bundle 20' can be melt-solidified, and the unfiber-opened staple fiber bundle 20' and the entire sheet can be melted and solidified. The sheets 11' are joined. By this bonding, a plurality of joints 13 can be formed (see Fig. 1).

The unfiber-opened staple fiber bundle 20' joined to the entire sheet 11' is supplied to a fiber opening step using the fluid ejecting device 55. In the fiber opening step, the constituent fibers 21 of the unfiber-opened staple fiber bundle 20' are disturbed by spraying a fluid to be opened. The degree of opening of the fiber 21 can be adjusted by adjusting the fluid ejection pressure or the like. In the case where air is used as the fluid, the degree of ejection is higher than that in the manufacturing method shown in Fig. 9. The reason for this is that the manufacturing method shown in Fig. 9 is to eject the fluid for the purpose of re-opening the fibers 21 in the opened state. In contrast, the present manufacturing method requires the unfiber-opened fibers 21 to be opened, so that the method is opened. Fiber needs more energy.

As described above, the block-shaped fiber assembly bundle 20 can be formed in a state of being fixed to the entire sheet body 11', and the long-length cleaning sheet body 10' can be obtained. Thereafter, the target cleaning sheet 10 can be obtained in the same order as the manufacturing method shown in FIG.

Next, the second to eighth embodiments of the present invention will be described with reference to Figs. 11 to 18 . In the above embodiments, only differences from the first embodiment will be described, and the description of the first embodiment can be appropriately applied without particular limitation. In addition, in FIGS. 11 to 18, the same components as those in FIGS. 1 to 10 are denoted by the same reference numerals.

In the cleaning sheet 10 of the second embodiment shown in Fig. 11, the type of the substrate sheet 11 is different from that of the first embodiment. Specifically, the base sheet 11 of the present embodiment includes a mesh (sparse yarn) 11a. The mesh 11a is a lattice shape. The mesh size, the wire diameter, and the line pitch are determined in consideration of the strength of the cleaning sheet 10 or the bonding property with the bulk fiber bundle 20 constituting the cleaning portion 12. Specifically, the mesh diameter of the mesh 11a is preferably from 10 to 5,000 μm, more preferably from 50 to 1,000 μm. The wire diameter of the mesh 11a may also be partially different. In this case, it is preferred that the wire diameter of the thicker portion is the above value. The line spacing of the mesh 11a is preferably 0.1 to 30 mm, more preferably 5 to 15 mm. The mesh 11a contains, for example, a synthetic resin. According to the cleaning sheet 10 of the present embodiment, the cleaning force of the sheet holding portion 104 and the mesh 11a is improved in a state where the cleaning sheet 10 is attached to the cleaning tool 100 shown in Fig. 4 .

In the cleaning sheet 10 of the third embodiment shown in Fig. 12, the type of the substrate sheet 11 is different from that of the first embodiment. Specifically, the base sheet 11 of the present embodiment includes a composite of a mesh (sparse yarn) 11a and a nonwoven fabric 11b. As the mesh 11a, the same as in the second embodiment can be used. As the nonwoven fabric 11b, the same as in the first embodiment can be used. The mesh 11a and the nonwoven fabric 11b are joined by, for example, heat welding or by using an adhesive. In the substrate sheet 11, the mesh 11a faces the cleaning portion 12 side, and the nonwoven fabric 11b faces the opposite side of the cleaning portion 12. According to the cleaning sheet 10 of the present embodiment, the same effects as those of the cleaning sheet of the embodiment shown in Fig. 11 can be exhibited.

The cleaning sheet 10 of the fourth embodiment shown in FIG. 13 is different from the first embodiment in that the cleaning portion has a plurality of lengthwise directions X. Specifically, the cleaning unit includes two of the first cleaning unit 12A and the second cleaning unit 12B. The width of each of the cleaning portions 12A and 12B is substantially equal. Moreover, the basis weight of the fibers 21 is also substantially equal. Each of the cleaning portions extends along the longitudinal direction X. The substrate sheet 11 is exposed between the two cleaning portions 12A and 12B. According to the cleaning sheet 10 of the present embodiment, in the case of cleaning the anti-slip strip of the step or the convex portion such as the lower frame of the door, the cleaning portion 12A, 12B is used to straddle the convex portion and enclose the convex portion therein. Since the cleaning is performed in this manner, there is an advantage that the followability of the convex portion or the trapping property of the dirt existing in the convex portion is further improved. From this point of view, the distance D between the first cleaning unit 12A and the second cleaning unit 12B is preferably 2 to 80 mm, preferably 10 to 50 mm.

Fig. 14 is a perspective view showing a fifth embodiment of the cleaning sheet of the present invention. The fiber assembly bundle constituting the cleaning portion 12 includes an aggregate of the unfiber-opened short fiber bundles 20'. The details of the unfiber-opened staple fiber bundle 20' are the same as those described above with reference to Fig. 3 . In the present specification, the term "unopened fiber" refers to a state in which a plurality of fibers are bundled in one direction. The fiber 21 extending from the joint portion 22 of the unfiber-opened staple fiber bundle 20' shown in Fig. 3 can be opened by friction with the surface to be cleaned during use of the cleaning sheet 10 of the present embodiment. By the fiber opening, the unfiber-opened staple fiber bundle 20' has a block shape and becomes the bulk fiber bundle 20 shown in the same figure. In addition, the block-shaped fiber bundle 20 shown in the same figure is a spherical shape, and is an ideal fiber opening state in the case where the unfiber-opened staple fiber bundle 20' is opened alone. Since the opening is performed in a state in which the pressure at the time of cleaning is applied to the cleaning unit 12, the bulk fiber bundle 20 has a flat shape having a constant thickness.

The unfiber-opened staple fiber bundle 20' used in the present embodiment is a flat shape as shown in Fig. 3. However, the shape of the unfiber-opened staple fiber bundle 20' is not limited thereto, and may be, for example, a columnar shape or a square column shape. Twisted (spiral).

In the cleaning sheet 10, the unfiber-opened staple fiber bundles 20' are randomly or regularly disposed on one surface of the substrate sheet 11, and joined to the substrate sheet 11 to form the cleaning portion 12. The unfiber-opened staple fiber bundles 20' may be disposed at intervals, or may be disposed at predetermined intervals so that the surface of the substrate sheet 11 is exposed between adjacent unfiber-opened staple fiber bundles 20'. Further, the unfiber-opened staple fiber bundles 20' may be disposed in a single layer or in a multi-layer configuration of two or more stages. In either case, the unfiber-opened staple fiber bundles 20' are advantageous in that the constituent fibers 21 are opened in a state of being rubbed by friction with the surface of the cleaning target, and the cleaning portion 12 has a uniform thickness. Configure in the state.

As shown in FIG. 14, the substrate sheet 11 and the unfiber-opened staple fiber bundle 20' are joined at the joint 13. The joint is formed by, for example, welding of the constituent fibers 21 of the substrate sheet 11 and the unfiber-opened staple fiber bundle 20'. Alternatively, it is formed by the substrate sheet 11 and the fiber 21 subsequently. The joint 13 can be configured regularly, Or configure it randomly. According to the manufacturing method described below, the joint 13 is regularly arranged.

The unfiber-opened staple fiber bundle 20' does not need to be joined to the substrate sheet 11 at the position of the joint portion 22. In other words, it is not necessary to form the joint 13 at the position of the joint portion 22. As long as the unfiber-opened staple fiber bundle 20' is bonded to the substrate sheet 11, the detachment from the substrate sheet 11 does not occur, and the unfiber-opened staple fiber bundle 20' is at any position of the unfiber-opened staple fiber bundle 20'. The substrate sheets 11 may be joined to each other.

The total basis weight of the unfiber-opened staple fiber bundles 20' constituting the cleaning portion 12 depends on the total fineness of the unfiber-opened staple fiber bundles 20' or the length of the fibers 21, but is preferably from 10 to 1,000 g/m ² , preferably. 50 to 500 g/m ² , the fiber 21 in the fiber-opening state is excellent in the wiping feeling in terms of the volume of the cleaning sheet 10 in which the fiber 21 is opened and the fiber 21 is opened. The aspect is better.

When the cleaning sheet 10 of the present embodiment is placed in the mounted state shown in FIG. 4 described above and the cleaning target surface is wiped, the fibers 21 of the unfiber-opened staple fiber bundle 20' are cleaned by the cleaning portion 12 and Clean the surface of the object and open the fiber. This state is the same as the state shown in FIGS. 1 and 2 described above. In the cleaning sheet 10 in which the fibers 21 are opened by cleaning, the cleaning unit 12 includes an assembly of the block-shaped fiber bundles 20 shown in Fig. 1 . The thickness of the cleaning sheet of the cleaning unit 12 depends on the degree of friction or the pressure applied during cleaning. However, in the fiber-opening state of the fiber 21, it is preferably 1 to 50 mm under a load of 300 Pa. It is preferably 2 to 30 mm.

In the state before the fiber opening, the fibers 21 constituting the unfiber-opened staple fiber bundle 20' mainly face the planar direction of the cleaning portion 12 as shown in FIG. The fibers 21 facing in the planar direction are not all oriented in the same direction, but in all directions in the plane. By opening the fibers 21 in this state, the fibers 21 after the opening are oriented in all directions in the plane of the cleaning portion 12 as shown in Figs. 1 and 2 described above. Further, in the fiber 21, a large amount of the direction toward the thickness direction of the cleaning portion 12 is also present. Therefore, in the both ends of the fiber 21, since one end becomes a free end, the degree of freedom of movement is extremely high. As described above, in the fiber-opening state, since the fibers 21 are oriented in various directions and the degree of freedom of movement is extremely high, the dirt can be caught between the fibers 21 regardless of the direction in which the cleaning sheet 10 is wiped.

Further, it is not necessary to perform special processing on the unfiber-opened staple fiber bundle 20' in order to open the fibers 21 of the unfiber-opened staple fiber bundle 20' well. The fibers are opened by applying friction to the fibers that are aligned in one direction, and the fibers should have properties. From the other side, it can be said that the present invention provides a cleaning sheet which can maintain a compact shape which is not fluffy before use and which has a high-definition performance which becomes fluffy by utilizing the related attributes. However, the fibers of the unfiber-opened staple fiber bundles 20' may be turned upside down before use, or combed with a comb or a brush, and rubbed, whereby the fibers 21 are well opened end to end.

Next, a preferred method of manufacturing the cleaning sheet 10 of the present embodiment will be described with reference to Fig. 15 . The manufacturing method can be roughly classified into (i) a manufacturing step of the unfiber-opened short fiber bundle 20', and (ii) a joining step of the unfiber-opened short fiber bundle 20' and the substrate sheet 11. (ii) Manufacturing process of the unfiber-opened staple fiber bundle 20' (manufacturing step) of the (a) bulk fiber bundle 20 when the cleaning sheet of the first embodiment is manufactured as described above with reference to Figs. 5 to 7 The steps are referred to, and the description thereof is omitted here. Moreover, only the steps of (ii) will be explained here.

The description will be made with reference to the steps of (ii) in Fig. 15. In the manufacturing apparatus 50 shown in Fig. 15, first, the entire sheet 11' is taken out from the entire sheet roll 11a of the substrate sheet 11. An unfiber-opened staple fiber bundle 20' is disposed on one surface of the drawn sheet body 11'. This configuration uses a suction device 51. The suction device 51 is provided with a suction pipe 52. One end of the suction tube 52 is located in a housing box 53 in which a plurality of unfiber-opened staple fiber bundles 20' are housed. The other end of the suction pipe 52 is located on the face at a predetermined interval from the face opposite to the face of the entire sheet 11'. The other end of the suction pipe 52 has a horizontally wide opening portion 52' extending in the width direction of the entire sheet body 11'.

The suction device 51 is activated, and the unfiber-opened staple fiber bundle 20' accommodated in the storage box 53 is sucked together with the air. By the suction, the unfiber-opened staple fiber bundle 20' is sucked into the tube 52 from one end of the suction tube 52, and is conveyed into the tube 52. Then, it is discharged through the other end of the tube 52, that is, the opening portion 52', and placed on the entire sheet body 11'. The unfiber-opened staple fiber bundle 20' is disposed in a disregarded manner. The desired number of unfiber-opened staple fiber bundles 20' can be disposed on the entire sheet body 11' by adjusting the degree of suction or the shape of the opening portion 52'.

The entire sheet 11' on which the unfiber-opened staple fiber bundle 20' is placed is introduced into the embossing device 54. This embossing device 54 is the same as the structure of the embossing device (see FIG. 9) for manufacturing the cleaning sheet of the first embodiment. Therefore, the description of the first embodiment can be suitably applied to the joining of the unfiber-opened staple fiber bundle 20' using the embossing device 54 to the entire sheet body 11'.

By the joining of the unfiber-opened staple fiber bundle 20' and the entire sheet body 11', the long-length cleaning sheet body 10' can be obtained. The sheet 10' is introduced into the width direction cutting device 56. The width direction cutting device 56 includes a first roller 56a that is disposed at a predetermined interval in the circumferential direction, and an anvil roller 56b that is disposed to face the first roller 56a. The two rolls 56a and 56b are arranged such that the ridge bar 56c of the first roll 56a comes into contact with the circumferential surface of the anvil roll 56b or a distance relationship close to the circumferential surface. By introducing the sheet body 10' into the width direction cutting device 56, the sheet body 10' can be cut at a predetermined interval along the width direction. By this cutting, the sheet body 10' can be made into a single piece, and the target cleaning sheet body 10 can be obtained.

Further, in the present manufacturing method, the chemical application device 35 described above with reference to FIGS. 5 and 7 may be provided at a position downstream of the embossing device 54 shown in FIG.

The type of the base sheet 11 of the cleaning sheet 10 of the sixth embodiment shown in Fig. 16 is different from that of the fifth embodiment. Specifically, the base sheet 11 of the present embodiment includes a mesh (sparse yarn) 11a. The details of the mesh 11a are the same as those described in the second embodiment shown in FIG. The cleaning sheet 10 of the present embodiment has an advantage of improving the engagement force between the sheet holding portion 104 and the mesh 11a in a state where it is attached to the cleaning tool 100 shown in Fig. 4 .

The type of the substrate sheet 11 of the cleaning sheet 10 of the seventh embodiment shown in Fig. 17 is also different from that of the fifth embodiment. Specifically, the base sheet 11 of the present embodiment includes a composite of a mesh (sparse yarn) 11a and a nonwoven fabric 11b. This embodiment is a combination of the fifth embodiment shown in Fig. 14 and the third embodiment shown in Fig. 12. According to the cleaning sheet 10 of the present embodiment, the same effects as those of the cleaning sheet of the sixth embodiment shown in Fig. 16 can be obtained.

The cleaning sheet 10 of the eighth embodiment shown in Fig. 18 is different from the fifth embodiment in that the cleaning portion has a plurality of lengths extending in the longitudinal direction X. This embodiment is a combination of the fifth embodiment shown in Fig. 14 and the fourth embodiment shown in Fig. 13.

Hereinabove, the present invention has been described based on preferred embodiments of the present invention, but the present invention is not limited to the above embodiments. For example, the block fiber bundle 20 and the unfiber-open staple bundle 20' of the above-described embodiments form the joint portion 22 in a substantially central region in the longitudinal direction of the fiber 21, and the joint portion 22 may be formed in the length of the deflecting fiber 21. The position of the approximate central region of the direction is replaced. Further, the joint portion 22 may be formed at one end of the fiber 21.

Further, as the bulk fiber bundle 20, a plurality of first fibers arranged in one direction and a plurality of second fibers arranged in a direction crossing the direction may be used, and formed by two fibers. The joint portion at the intersection is configured by joining the two fibers to each other, and the first and second fibers extending from the joint portion are opened to form a block. The same applies to the unfiber-opened staple fiber bundle 20'.

Moreover, in each of the above-described embodiments, an example in which the cleaning sheet 10 is attached to the cleaning tool shown in FIG. 4 is used, and instead, the cleaning sheet 10 may be used as the applicant. A cleaning cloth having a flat bag shape having an insertion space as described in Japanese Laid-Open Patent Publication No. Hei 9-299305, and the cleaning cloth is attached to the hand-held mop type cleaning device described in the same publication. Alternatively, the cleaning sheet 10 may be directly held for cleaning.

Further, in each of the above embodiments, the cleaning portion 12 is formed only on one surface of the base sheet body 11, but the cleaning portion 12 may be formed on both surfaces of the base sheet body 11 instead.

Further, an embodiment in which the substrate sheet shown in Figs. 11 and 12 and the cleaning portion shown in Fig. 13 are appropriately combined is also included in the scope of the present invention. Similarly, an embodiment in which the substrate sheet shown in Figs. 16 and 17 and the cleaning unit shown in Fig. 18 are appropriately combined is also included in the scope of the present invention.

Example

Hereinafter, the present invention will be described in more detail based on examples. However, the scope of the invention is not limited to the embodiments.

[Example 1-1]

(1) Manufacture of unfiber-opened staple fiber bundles

The unfiber-opened staple fiber bundle 20' was produced in accordance with the method shown in FIG. The fiber 21 used is a core-sheath type composite fiber in which polyethylene terephthalate is a polyethylene terephthalate and a sheath is polyethylene. The fiber has a fineness of 2.2 dtex. The number of crimps of the fibers 21 was 16.51, and the crimp height was 0.87 mm. The fiber length is approximately 45 mm. The unfiber-opened staple fiber bundle 20' has a total fineness of about 3700 tex and a weight of about 0.13 g. The width of the joint portion 22 of 5 mm is formed in a substantially central region in the longitudinal direction of the fiber 21. On the unfiber-opened staple fiber bundle 20', a mobile paraffin wax of 5% by weight based on the weight thereof was applied as an oil agent.

(2) Manufacture of bulk fiber bundles

The obtained unfiber-opened staple fiber bundle 20' is opened by using the apparatus shown in Fig. 8 to obtain a bulk fiber bundle 20. The obtained bulk fiber bundle 20 has a joint portion 22 in a substantially central portion thereof, and a fiber-like (celescens-like) shape in which the fibers 21 radially extend from the joint portion 22. Its volume is approximately 8 cm ³ .

(3) Manufacture of cleaning sheets

The cleaning sheet 10 was produced using the apparatus shown in FIG. As the substrate sheet 11, a hot air non-woven fabric having a basis weight of 40 g/m ² was used. The nonwoven fabric comprises a polyester/polyethylene core sheath type composite fiber having a fineness of 2.2 dtex. The length of the substrate sheet 11 in the longitudinal direction X was 280 mm, and the length in the width direction Y was 210 mm. On one surface of the substrate sheet 11, 40 block-shaped fiber bundles 20 were laid in a single layer without ignoring and without gaps. The area to be laid is a region extending over the entire length direction X in a range in which the length of the central portion in the width direction Y of the substrate sheet 11 is 120 mm. The cleaning unit 12 is formed by joining the bulk fiber bundle 20 to the base sheet 11 by heat welding. The joint 13 is a circle having a diameter of 3 mm. The arrangement pattern of the joints 13 is a lattice shape. The distance between the joints 13 is 20 mm in both the longitudinal direction X and the width direction Y. The total basis weight of the bulk fiber bundles 20 on the cleaning portion 12 was 155 g/m ² . Thus, the cleaning sheet 10 shown in Fig. 1 is obtained.

[Example 1-2]

The cleaning sheet 10 shown in Fig. 1 was obtained in the same manner as in Example 1-1 except that the number of crimps was 22.32 and the crimp height was 0.32 mm.

[Example 1-3]

The cleaning sheet 10 shown in Fig. 1 was obtained in the same manner as in Example 1-1 except that the number of crimps was 7.5 and the crimp height was 0.07 mm.

[Example 1-4]

The cleaning sheet 10 shown in Fig. 1 was obtained in the same manner as in Example 1-1 except that the number of crimps was 22.86, the crimp height was 0.24 mm, and the fineness was 4.4 dtex.

[Example 1-5]

The cleaning sheet 10 shown in Fig. 13 was produced. The fiber 21 and the bulk fiber bundle 20 used were the same as in Example 1-1. The length of the first cleaning unit 12A and the second cleaning unit 12B in the width direction Y is 50 mm. The distance D between the first cleaning unit 12A and the second cleaning unit 12B is 20 mm. The basis weight of each of the cleaning portions 12A and 12B was 155 g/m ² . Otherwise, the cleaning sheet 10 was obtained in the same manner as in Example 1-1.

[Example 1-6]

In Example 1-5, the two cleaning portions were changed to three. The length of each cleaning portion in the width direction Y was 30 mm. The distance between each cleaning portion is 10 mm. The cleaning sheet 10 was obtained in the same manner as in Example 1-5 except that the basis weight of each of the cleaning portions was 155 g/m ² .

[Comparative Example 1]

A Quickle (registered trademark) dried sheet manufactured by Kao Co., Ltd. was used as Comparative Example 1.

[Evaluation]

With respect to the cleaning sheet obtained in the examples and the comparative examples, the thickness of the cleaning portion was measured under a load of 300 Pa. The results are shown in Table 1. In addition, the cleaning sheet obtained in the examples and the comparative examples was attached to the head of a Quickle (registered trademark) mop manufactured by Kao Co., Ltd., and the cleaning sheet was evaluated for various cleaning objects having irregularities as follows. The follow-up of the face and the capture of dirt. The results are shown in Table 1. As the surface to be cleaned, (a) the groove of the wooden floor (the KER7UE V groove depth of 1km and the width of 2mm by the National Corporation), (b) the tatami (the rush part), and the (c) vertical surface (the wall in the room) Plate part: QPL113T39 manufactured by National Corporation, (d) sill (4 mm groove width, width 21 mm), (e) sliding door sliding door (Barrier free type groove depth 2 mm, width 5.3 mm) ), (f) the side of the door stop (the suspended MJT107 manufactured by National Corporation), (g) the frame below the door (height 15mm, width 30mm), and (h) the anti-slip strip of the step (made by Kawaguchi Tech Co., Ltd.) ", height 3.9mm, width 39.5mm). 0.02 g of Model Dust "Cotton velvet manufactured by IWAMOTO MINERAL Co. LTD, having a diameter of less than 10 μm and a length of less than 0.5 mm" was weighed and spread on a surface of various cleaning objects having irregularities by using a sieve having a pore size of 300 μm. The cleaning sheet was attached to the head of a Quickle (registered trademark) mop manufactured by Kao Co., Ltd., and rubbed back and forth twice in pursuit of the cleaning surface. After wiping, the Model Dust remaining on the uneven portion of the cleaning surface and the peripheral portion of the uneven portion was visually observed and judged.

The evaluation criteria are as follows.

‧Complicability

◎: no residue in the uneven portion

○: Within about 1/4 of the amount of dispersion remaining in the uneven portion

△: Within about 1/2 of the amount of dispersion remaining in the uneven portion

×: about 1/2 of the amount of scattering remaining in the uneven portion

‧Capturing

◎: no residue in the peripheral portion including the uneven portion

○: Within about 1/4 of the amount of dispersion remaining in the peripheral portion including the uneven portion

△: Within about 1/2 of the amount of dispersion remaining in the peripheral portion including the uneven portion

×: about 1/2 of the amount of scattering remaining in the peripheral portion including the uneven portion

As a result of the results shown in Table 1, it was found that the cleaning sheet of each of the examples was superior to the cleaning sheet of the comparative example in that the surface of the cleaning sheet was excellent in the followability of the uneven surface and the dirt was highly trapped.

[Example 2-1]

(1) Manufacture of unfiber-opened staple fiber bundles

An unfiber-opened staple fiber bundle 20' produced by the same method as that of Example 1-1 was used.

(2) Manufacture of cleaning sheets

The cleaning sheet 10 was produced using the apparatus shown in Fig. 15 . As the substrate sheet 11, the same as the substrate sheet used in Example 1-1 was used. On one surface of the substrate sheet 11, 40 unfiber-opened staple fiber bundles 20' were arranged in a single layer. The area to be disposed is a region extending over the entire length direction X in a range in which the length of the central portion in the width direction Y of the substrate sheet 11 is 120 mm. The unfibered short fiber bundle 20' is joined to the substrate sheet 11 by heat welding to form the cleaning portion 12. The joint 13 is a circle having a diameter of 3 mm. The arrangement pattern of the joints 13 is a lattice shape. The distance between the joints 13 is 20 mm in both the longitudinal direction X and the width direction Y. The unfiber-opened staple fiber bundle 20' in the cleaning portion 12 has a total basis weight of 155 g/m ² . Thus, the cleaning sheet 10 shown in Fig. 14 is obtained.

[Example 2-2]

The cleaning sheet 10 shown in Fig. 14 was obtained in the same manner as in Example 2-1 except that the number of crimps was 22.32 and the crimp height was 0.32 mm.

[Example 2-3]

The cleaning sheet 10 shown in Fig. 14 was obtained in the same manner as in Example 2-1 except that the number of the crimps was 7.5 and the crimp height was 0.07 mm.

[Example 2-4]

The cleaning sheet 10 shown in Fig. 14 was obtained in the same manner as in Example 2-1 except that the number of crimps was 22.86, the crimp height was 0.24 mm, and the fineness was 4.4 dtex.

[Example 2-5]

The cleaning sheet 10 shown in Fig. 18 was produced. The fiber 21 and the unfiber-opened staple fiber bundle 20' used were the same as those in Example 2-1. The length of the first cleaning portion 12A and the second cleaning portion 12B in the width direction Y in the fiber opening state is 50 mm. The distance D between the first cleaning unit 12A and the second cleaning unit 12B in the opened state is 20 mm. The basis weight of each of the cleaning portions 12A and 12B was 155 g/m ² . Otherwise, the cleaning sheet 10 was obtained in the same manner as in Example 2-1.

[Example 2-6]

In Example 2-5, the two cleaning sections were changed to three. The length of each cleaning portion in the fiber opening state in the width direction Y is 30 mm. The distance between each cleaning portion in the fiber opening state was 10 mm. The basis weight of each cleaning portion was 155 g/m ² . Otherwise, the cleaning sheet 10 was obtained in the same manner as in Example 2-5.

[Evaluation]

With respect to the cleaning sheet obtained in the examples and the comparative examples, the thickness of the cleaning portion before cleaning was measured under a load of 300 Pa. Moreover, after the fiber was opened by cleaning, the same measurement as described above was carried out. The results are shown in Table 2. Further, with respect to the cleaning sheet obtained in the examples and the comparative examples, the cleaning sheet was evaluated for the followability and dirt to the various cleaning target surfaces having irregularities by the same method as in Example 1-1. Capture. The results are shown in Table 2. Further, in order to facilitate the comparison, Table 2 again describes the data of Comparative Example 1 described in Table 1.

From the results shown in Table 2, it was found that the cleaning sheets of the respective examples had a small thickness before cleaning, but the fibers were opened by the cleaning and became bulky. Moreover, it is understood that the cleaning sheet of each of the examples is superior to the cleaning sheet of the comparative example in that the surface of the cleaning sheet is excellent in the followability of the uneven surface and the dirt is highly trapped.

Industrial availability

As described in detail above, according to the present invention, it is possible to provide a cleaning sheet having excellent followability to a cleaning target surface having irregularities, excellent dirt trapping property and capturing efficiency, and a volumetric feeling and a good wiping feeling. Moreover, when the unfiber-opened staple fiber bundle is used, when the surface of the cleaning target is wiped, the fibers are opened in all directions and become bulky, and the fibers are in an unopened state before use, so that they do not become fluffy. Keep it in a tight state.

3‧‧‧Opening device

10. . . Cleaning sheet

10'. . . Cleaning sheet

11. . . Substrate sheet

11'. . . Whole piece

11a. . . Wing

11a. . . Whole sheet roll

11a. . . Mesh

11b. . . Non-woven

12. . . Cleaning department

12A. . . First cleaning department

12B. . . Second cleaning department

12a. . . Sweep the left and right edges

13. . . Joint

20. . . Bulk fiber bundle

20'. . . Unfibered staple fiber bundle

twenty one. . . fiber

22, 22'. . . Joint

twenty three. . . Bunch of continuous long fibers

twenty four. . . Open fiber tow

25. . . Continuous filament bundle

26. . . Split open fiber bundle

30. . . Manufacturing device

31. . . Supply department

32. . . Fiber opening device

33. . . Grooved roll

34. . . Anvil roll

35. . . Chemical coating device

36. . . Jointing device

36a, 36b. . . Embossing roller

36c. . . Rib

37. . . Cutting machine

37a. . . First roller

37b. . . Anvil roll

38. . . Width direction cutting device

39. . . Split device

40. . . Chamber

41. . . Import department

42. . . Discharge department

50. . . Manufacturing device

51. . . Suction device

52. . . Suction tube

52'. . . Opening

53. . . Storage box

54. . . Embossing device

54a. . . First roller

54b. . . Anvil roll

54c. . . Protrusion

55. . . Fluid ejection device

56. . . Width direction cutting device

56a. . . First roller

56b. . . Anvil roll

56c. . . Convex knife

100. . . Sweeping tool

101. . . head

102. . . handle

103. . . Universal joint

104. . . Sheet holder

X. . . Longitudinal direction

Y. . . Width direction

d. . . Width of the joint

D. . . Distance between the first cleaning unit and the second cleaning unit

Fig. 1 is a perspective view showing a first embodiment of the cleaning sheet of the present invention.

Figure 2 is a cross-sectional view taken along line II-II of Figure 1.

Fig. 3 is a perspective view showing an unfiber-opened staple fiber bundle and a bundle of bulk fibers.

Fig. 4 is a perspective view showing a use form of one of the cleaning sheets shown in Fig. 1;

Fig. 5 is a schematic view showing a manufacturing apparatus of an unfiber-opened staple fiber bundle.

6(a) to (d) are schematic views showing the manufacturing process of the unfiber-opened staple fiber bundle in order.

Figure 7(a) is a schematic view showing another manufacturing apparatus of the unfiber-opened staple fiber bundle, and Figure 7(b) is a view showing a part of the manufacturing process of the unfiber-opened staple fiber bundle using the manufacturing apparatus shown in Figure 7(a). Pattern diagram.

Fig. 8 (a) and (b) are schematic views showing a fiber opening device of an unfiber-opened staple fiber bundle.

Fig. 9 is a schematic view showing a manufacturing apparatus for a sheet for cleaning.

Fig. 10 is a schematic view showing another manufacturing apparatus for the cleaning sheet.

Fig. 11 is a perspective view showing a second embodiment of the cleaning sheet of the present invention (corresponding to Fig. 1).

Fig. 12 is a perspective view showing a third embodiment of the cleaning sheet of the present invention (corresponding to Fig. 1).

Fig. 13 is a perspective view showing a fourth embodiment of the cleaning sheet of the present invention (corresponding to Fig. 1).

Fig. 14 is a perspective view showing a fifth embodiment of the cleaning sheet of the present invention.

Fig. 15 is a schematic view showing a manufacturing apparatus of the cleaning sheet shown in Fig. 14;

Fig. 16 is a perspective view showing a sixth embodiment of the cleaning sheet of the present invention (corresponding to Fig. 14).

Fig. 17 is a perspective view showing a seventh embodiment of the cleaning sheet of the present invention (corresponding to Fig. 14).

Fig. 18 is a perspective view (corresponding to Fig. 14) showing an eighth embodiment of the cleaning sheet of the present invention.

10. . . Cleaning sheet

11. . . Substrate sheet

11a. . . Wing

12. . . Cleaning department

12a. . . Sweep the left and right edges

13. . . Joint

20. . . Bulk fiber bundle

X. . . Longitudinal direction

Y. . . Width direction

Claims (10)

A cleaning sheet for forming a cleaning portion by bonding a plurality of bundles of a plurality of block fibers on at least one surface of a substrate sheet, the bundle of bundle fibers being arranged in a plurality of directions in one direction by a joint portion The fibers are joined to each other, and the fibers extending from the joint portion are in an open state, wherein the bundle of the bulk fibers is randomly disposed on the base sheet, the bundle of the bundle fibers and the substrate The sheet system is joined at joints that can be configured regularly or randomly. The cleaning sheet according to claim 1, wherein the joint portion is formed in a substantially central portion of the fiber in the longitudinal direction of the bundle. The sheet for cleaning according to claim 1, wherein the fiber has a crimp. The cleaning sheet of claim 2, wherein the fiber has a crimp. The cleaning sheet according to any one of claims 1 to 4, wherein the substrate sheet comprises a mesh. The cleaning sheet according to any one of claims 1 to 4, wherein the substrate sheet is attached to the head having a head and a cleaning device attached to the handle of the head. The cleaning sheet according to claim 5, wherein the substrate sheet is attached to the head having a head and a cleaning tool attached to the handle of the head. A method for manufacturing a sheet for cleaning, which is manufactured as claimed in claim 1 A method of sweeping a sheet by combining a plurality of continuous filaments arranged in one direction with a plurality of joints extending in a direction crossing a direction in which the fibers extend, to form a continuous long fiber bundle The continuous long fiber bundle is cut between the joint portions to obtain an unfiber-opened short fiber bundle, and a fluid is sprayed onto the unfiber-opened short fiber bundle, and fibers extending from the joint portion are opened to obtain a block-shaped fiber assembly. The bundle is formed by bonding a plurality of the above-mentioned bundles of bulk fibers to at least one side of the substrate sheet. A bundle of bulk fibers for use as a cleaning portion of the cleaning sheet according to claim 1, wherein the bundle of fibers is joined to each other by a plurality of fibers arranged in one direction by a joint portion. The fiber is configured to extend from the joint portion in an open state. A method for producing a bundle of bundled fibers, the bundle of bundles of fibers according to claim 9, wherein the method of manufacturing comprises a plurality of continuous filaments arranged in one direction A plurality of joint portions extending in a direction intersecting the extending direction of the fibers are joined to each other to form a continuous long fiber bundle, and the continuous long fiber bundle is cut between the joint portions to obtain an unfiber-opened short fiber bundle, and the fluid is sprayed To the unfiber-opened staple fiber bundle, the fiber extending from the joint portion is opened.