US20160230320A1 - Sheet manufacturing apparatus, sheet manufacturing method, sheet manufactured with the same, composite used therewith and accommodation container therefor - Google Patents

Sheet manufacturing apparatus, sheet manufacturing method, sheet manufactured with the same, composite used therewith and accommodation container therefor Download PDF

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Publication number
US20160230320A1
US20160230320A1 US15/023,064 US201415023064A US2016230320A1 US 20160230320 A1 US20160230320 A1 US 20160230320A1 US 201415023064 A US201415023064 A US 201415023064A US 2016230320 A1 US2016230320 A1 US 2016230320A1
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United States
Prior art keywords
composite
fibers
resin
sheet
unit
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Abandoned
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US15/023,064
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English (en)
Inventor
Yoshihiro Ueno
Shunichi Seki
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Seiko Epson Corp
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Seiko Epson Corp
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Assigned to SEIKO EPSON CORPORATION reassignment SEIKO EPSON CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SEKI, SHUNICHI, UENO, YOSHIHIRO
Publication of US20160230320A1 publication Critical patent/US20160230320A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/736—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged characterised by the apparatus for arranging fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/64—Paper recycling

Definitions

  • the present invention relates to a sheet manufacturing apparatus, a sheet manufacturing method, a sheet manufactured with the same, a composite used therewith and an accommodation container therefor.
  • the paper manufactured by pulp molding generally includes a structure by cellulose fibers derived from wood or the like being entangled with one another, and being partially bonded to one another by a binder (paper strengthening agent (such as a starch paste and a water-soluble resin)).
  • the fibers According to the pulp molding, it is possible for the fibers to be deposited in a state where uniformity is favorable, and, in a case where a paper strengthening agent is used in the bonding between fibers, it is possible for the paper strengthening agent to be dispersed (distributed) in a state where the uniformity in the paper surface is good.
  • the pulp molding is a wet method, it is necessary to use large volumes of water, and the necessity of dewatering and drying or the like arises after forming the paper, and therefore the energy or time consumed is extremely large. It is necessary to suitably process the water used as waste water. Accordingly, it is difficult to respond to modern demands for energy savings, environmental protection, and the like.
  • PTL 1 discloses a waste paper board formed by mixing and defibrating waste paper pulp and a thermal fusion bondable powder with a dry method, and subjecting these to hot pressing or the like.
  • a coloring material such as a pigment
  • PTL 1 does not disclose the using of a coloring material.
  • the pigment is detached due to outside forces such as undulation, impact, abrasion or the like in a case of forming a sheet by simply mixing the coloring material.
  • thermal fusion bondable powders coagulate with each other by simply mixing.
  • a problem arises of possibly forming parts where the thermal fusion bondable powder becomes rough, not sufficiently bonding the pulp to each other at these parts, and lowering the strength of the sheet.
  • the invention was created in order to solve at least a part of the above problems, and can be realized in the following aspects or application examples.
  • a sheet manufacturing apparatus including a mixing unit in which fibers and a composite integrally including a resin and a coloring material are mixed, and a bonding unit that bonds the fibers and the composite.
  • the composite integrally includes a coloring material and a resin and thus the coloring material is not easily detached from the composite. Since the composite and the fibers are bonded, the coloring material is also not easily detached from the fibers. Therefore, it is possible to manufacture a sheet in which color unevenness is suppressed.
  • the composite may further integrally include a coagulation inhibitor.
  • the composite since the composite also integrally includes a coagulation inhibitor, it is possible to suppress coagulation of the composite in the vicinity.
  • the composite includes the coagulation inhibitor as a separate body, the coagulation inhibition effect is not exhibited if the coagulation inhibitor is not present between the composite and the composite, in contrast, because the coagulation inhibitor is integrally included if the composite according to the invention is used, it is possible to reliably exhibit the coagulation inhibition effect. Therefore, because it is possible for the composite to be dispersed and mixed with respect to the fibers in the mixing unit, and more uniform mixing is performed, it is possible to manufacture a sheet with higher mechanical strength, and more favorable uniformity of the tone.
  • the composite may be a powder.
  • the composite since the composite easily enters between fibers because the composite is a powder compared to another shape of composite, such as a sheath shape, in the mixing unit, a more uniform mixture is possible, and it is possible to manufacture a sheet with higher mechanical strength and more favorable uniformity of the tone.
  • the size of the composite may be the thickness of the fibers or less.
  • the composite because the size of the composite is the thickness of the fibers or less, the composite easily enters between the fibers in contrast to not easily entering between the fibers when the size of the composite is larger than the thickness of the fibers, and because mixing is more uniformly performed in the mixing unit, it is possible to manufacture a sheet with higher mechanical strength, and more favorable uniformity of the tone.
  • the coloring material may be encapsulated in the resin.
  • the coloring material is positioned further to the inside than the surface of the resin, the coloring material does not easily drop off from the resin even by friction such as rubbing the manufactured sheet with a finger, and it is possible to manufacture a favorable sheet with a more uniform tone.
  • a sheet manufacturing method including a step of mixing fibers and a composite integrally including a resin and a coloring material; and a step of bonding the fibers and the composite.
  • a sheet including a raw material including fibers and a composite integrally including a resin and a coloring material, in which the fibers and the composite are bonded.
  • the coloring material is held by the resin of the composite in such a sheet, the coloring material is not easily detached.
  • an accommodation container which accommodates a composite used mixed with the fibers and integrally including the resin and the coloring material.
  • the coloring material is easily held by the resin when such a composite is mixed with the fibers, the coloring material is not easily detached.
  • a composite used in a sheet manufacturing apparatus and integrally including the resin and the coloring material.
  • the coloring material is easily held by the resin in such a composite, the coloring material is not easily detached from the manufactured sheet.
  • a sheet manufacturing apparatus including a mixing unit in which fibers and a composite integrally including a resin and a coagulation inhibitor are mixed, and a bonding unit that bonds the fibers and the composite.
  • the composite integrally includes the coagulation inhibitor and the resin because the composite integrally includes the coagulation inhibitor and the resin, coagulation of the resin is suppressed. Therefore, the resin is dispersed in the entire sheet and it is possible to manufacture a high strength sheet.
  • the composite may be a powder.
  • the composite is a powder, compared to another shape of composite, such as a sheath shape, the composite easily enters between the fibers during mixing. Therefore, more uniform mixing is possible, and it is possible to manufacture a high strength sheet.
  • a sheet manufacturing method including a step of mixing fibers and a composite integrally including a resin and a coagulation inhibitor; and a step of bonding the fibers and the composite.
  • the resin does not easily coagulate due to the coagulation inhibitor integrated with the resin, and it is possible to manufacture a high strength sheet.
  • a sheet including a raw material including fibers and a composite integrally including a resin and a coagulation inhibitor, in which the fibers and the composite are bonded.
  • the resin does not easily coagulate due to the coagulation inhibitor integrated with the resin, and the strength becomes high.
  • an accommodation container which accommodates a composite used mixed with fibers and integrally including the resin and the coagulation inhibitor.
  • a composite integrally including a resin and a coagulation inhibitor and used mixed with the fibers.
  • the resin does not easily coagulate due to the integrated coagulation inhibitor when such a composite is mixed with the fibers, the resin is easily dispersed with respect to the fibers.
  • a composite used in a sheet manufacturing apparatus and integrally including the resin and the coagulation inhibitor.
  • the resin does not easily coagulate due to the integrated coagulation inhibitor in such a composite, the resin is easily dispersed across the entire sheet. Therefore, since it is possible to manufacture a high strength sheet, effective use in the sheet manufacturing apparatus is possible.
  • FIG. 1 is a schematic view of the main portions of a sheet manufacturing apparatus according to an embodiment.
  • FIG. 2 is a schematic view of the sheet manufacturing apparatus according to the embodiment.
  • FIG. 3 is a diagram showing an example of a configuration of the sheet manufacturing apparatus.
  • FIG. 4 shows schematic views of several examples of cross-sections of a composite according to the embodiment.
  • the sheet manufacturing apparatus 1000 according to the embodiment is provided with a mixing unit 100 and a bonding unit 200 .
  • FIG. 1 is a schematic view of the main portions the sheet manufacturing apparatus 1000 according to the embodiment.
  • FIG. 2 is a schematic view of the sheet manufacturing apparatus 1000 according to the embodiment.
  • FIG. 3 is a diagram showing an example of a configuration of the sheet manufacturing apparatus 1000 of the embodiment.
  • the sheet manufacturing apparatus 1000 is provided with at least a mixing unit 100 and a bonding unit 200 .
  • the mixing unit 100 has the function of causing the fibers (fibrous material) and the composite integrally including a resin and a coloring material to be mixed. At least the fibers and the composite are mixed in the mixing unit 100 .
  • particles formed with resin as a main component integrated with other components are referred to when referring to the composite.
  • other components refers to coloring materials or coagulation inhibitors, and the like, shapes, sizes, materials or components having functions different to the resin that is the main component are also included.
  • the wording “the fibers and the composite are mixed together” is defined as the composite being positioned between the fibers in a space (system) with a fixed volume.
  • the composition, the structure, the mechanism and the like are not particularly limited.
  • the form of the mixing process in the mixing unit 100 may be batch processing, or may be either of a serial processing or continuous processing.
  • the mixing unit 100 may be operated manually or may be operated automatically. Although the mixing unit 100 causes at least the fibrous material and the composite to be mixed together, other components may also be mixed together.
  • mechanical mixing or fluid dynamic mixing as an example of the mixing process in the mixing unit 100 .
  • the mechanical mixing include methods of introducing the fibers (fibrous material) and the composite into a Henschel mixer, a blower or the like and agitating with rotating blades, and methods sealing the fibers (fibrous material) and the composite in a bag and shaking the bag.
  • the fluid dynamic mixing process include methods of introducing the fibers (fibrous material) and the composite in an airflow of the atmosphere or the like and diffusing the fibers (fibrous material) and the composite into one another in the airflow.
  • the composite may be fed into a pipe or the like in which the fibers of the fibrous material flow (transfer) by the airflow, or the fibers (fibrous material) may be fed into a pipe or the like in which the particles of the composite flow (transfer) by the airflow.
  • this is more preferable because the airflow in the pipe or the like being turbulent makes the mixing together efficient.
  • the mixing unit 100 is provided on the upstream side of a bonding unit 200 , described later, in the flow direction of (a portion of) the raw material in the sheet manufacturing apparatus 1000 .
  • Other configurations may be included between the mixing unit 100 and the bonding unit 200 . Examples of such other configurations include a forming unit that forms the mixture of the mixed fibers (fibrous material) and the composite into a web shape.
  • the mixture (below, may be referred to as “mixed material”) mixed together by the mixing unit 100 may be further mixed by another configuration such as a sheet forming unit.
  • the mixing unit 100 in a case of employing the pipe 86 as described above for the transfer of the fibers, there are methods of introducing the composite a state in which the fibers are caused to flow by the airflow of the atmosphere or the like.
  • the generator of the airflow in the case of employing the pipe 86 in the mixing unit 100 include a blower, not shown, and, as long as the above functions are obtained, it is possible to use any generator, as appropriate.
  • the introduction of the composite in the case of employing the pipe 86 in the mixing unit 100 to be performed by the opening and closing operation of a valve or the hand of a user
  • a screw feeder or a disk feeder not shown, or the like as the composite supplying unit 150 shown in FIGS. 1 and 2 .
  • this is more preferable.
  • the same also applies in a case of transferring the composite with the airflow and introducing the fibrous material to the airflow.
  • the sheet manufacturing apparatus 1000 of the embodiment it is preferable to select a dry-type form of the mixing unit 100 .
  • dry-type in the mixing refers to the state of being mixed together in air rather than in water. That is, the mixing unit 100 may function in the drying state, or may function in a state where a liquid present as an impurity or an intentionally added liquid is present. In the case of intentionally adding the liquid, it is preferable for the liquid to be added to an extent that the energy and time for removing the liquid through heat or the like do not increase excessively in later processes.
  • the sheet manufacturing apparatus 1000 is provided with a bonding unit 200 .
  • the bonding unit 200 is installed further to the downstream side in the flow of the raw material than at least the above-described mixing unit 100 .
  • the bonding unit 200 has a function of forming the fibers (fibrous material) and the composite mixed together in the above-described mixing unit 100 , that is, a mixed material, into a predetermined shape.
  • a state in which the fibers and the composite are bonded is achieved.
  • the wording “bonding the fibers and the composite” refers to a state in which the fibers and the composite are not easily separated, or a state in which the resin of the composite is arranged between the fibers, and the fibers become difficult to separate via the composite.
  • the wording “bonding” is the concept that includes bonding and includes a state in which two or more types of substance come into contact and are not easily separated.
  • the fibers may be parallel to or intersect one another when the fibers are bonded via the composite, or a plurality of fibers may be bonded to form one fiber.
  • the plurality of fibers is bonded via the composite by applying heat to the fibers and the composite mixed together in the mixing unit 100 .
  • resin that is one constituent component of the composite is a thermoplastic resin
  • the resin softens or melts, and is fixed by the temperature lowering. It is possible for the fibers and the composite to bond to one another by the fibers coming into contact so as to become entangled with the resin softened, and the resin hardening. The fibers bond to each other by other fibers bonding when solidified.
  • the resin of the composite is a heat-curable resin
  • the resin may be heated to the temperature of the softening point or higher, or may be heated to the curing temperature (temperature at which the curing reaction arises) or higher and it is possible to bond the fibers and the resin.
  • the melting point, the curing point, the curing temperature and the like of the resin is lower than the melting point, the decomposition temperature, and the carbonization temperature of the fibers, and it is preferable that the type of both is combined and selected so as to have such a relationship.
  • pressure may be applied in addition to applying heat to the mixed material, and in this case, the bonding unit 200 includes a function of forming the mixed material into a predetermined shape.
  • the magnitude of the pressure applied is regulated, as appropriate, according to the type of sheet formed, and 50 kPa or more to 30 MPa or less is possible. If the added pressure is low, a sheet with a large porosity is obtained, and if high, a sheet with a low porosity (high density) is obtained.
  • Examples of the specific configuration of the bonding unit 200 include, in addition to the heater roller 76 and the tension roller 77 as shown in FIGS. 1 and 2 , a calendar roller, a hot press molding machine, a hotplate, a hot air blower, an infrared heating device and a flash fixing device.
  • the sheet manufacturing apparatus 1000 of the embodiment may include, as appropriate, a configuration for preprocessing, a configuration for intermediate processing, a configuration for post processing and the like, in addition to the above-described mixing unit 100 and bonding unit 200 .
  • FIG. 2 schematically shows an example of the sheet manufacturing apparatus 1000
  • FIG. 3 shows an example of the configuration of the sheet manufacturing apparatus 1000 .
  • Examples of the configurations for preprocessing that is a configuration that performs processing of the fibers (fibrous material) or composite introduced to the mixing unit 100 include the crushing unit 10 (shredder or the like) that cuts the pulp sheet or waste paper or the like as a raw material in air, the defibrating unit 20 that untangles the raw material in air into a fiber form, the classifying unit 30 that classifies impurities (toner or paper strengthening agent) from the defibrated material that is defibrated and the fibers (short fibers) shortened by the defibration in air, and the screening unit 40 that screens the long fibers (long fibers) from the defibrated material and the undefibrated pieces that are insufficiently defibrated in air.
  • the crushing unit 10 shredder or the like
  • the defibrating unit 20 that untangles the raw material in air into a fiber form
  • the classifying unit 30 that classifies impurities (toner or paper strengthening agent) from the de
  • Examples of the configuration for the intermediate processing that is a configuration for performing appropriate processing until the composite and the fiber (mixed material) mixed by the mixing unit 100 are introduced to the bonding unit 200 include the distribution unit 60 that causes the mixed material to descend while being dispersed in air, and a sheet forming unit 70 that deposits the mixed material caused to descend from the distribution unit 60 and forms the mixed material into the shape of a web.
  • the bonding unit 200 may be a portion of the sheet forming unit 70 .
  • Examples of the configuration for post processing that is a configuration that performs processing on the sheet S formed by the bonding unit 200 include the drying unit 80 ( FIG. 3 ) which causes the sheet S to be dried as necessary, a winding unit 90 that winds the formed sheet into a roll shape, a cutting unit 92 ( FIG. 3 ) that cuts the formed sheet into a stipulated side, and a packaging unit 94 ( FIG. 3 ) that packages the wound or cut sheet with a film or packaging paper.
  • the sheet manufacturing apparatus 1000 of the embodiment prefferably has configurations other than the configurations given as examples above, and possible to have, as appropriate, a plurality of configurations according to the purpose with the above-described configuration included.
  • the order of each configuration is not limited, and is able to be designed, appropriate, according to the purpose.
  • the crushing unit 10 cuts the raw material, such as the pulp sheet or fed sheet (for example, A4 sized waste paper) in air into small pieces.
  • the shape and size of the small pieces although not particularly limited, is, for example, several cm squared.
  • the crushing unit 10 includes a crushing blade 11 , and it is possible for the fed raw materials to be cut by the crushing blade 11 .
  • An automatic feeding unit (not shown) for continuously feeding the raw material may be provided in the crushing unit 10 .
  • the small pieces cut by the crushing unit 10 are transported to the defibrating unit 20 via the first conveyance unit 81 when received by the hopper 15 .
  • the first conveyance unit 81 is communicated with the introduction port 21 of the defibrating unit 20 .
  • the shape of the first conveyance unit 81 and the second to sixth conveyance units 82 to 86 is a pipe shape.
  • the sixth conveyance unit 86 configures a portion of the mixing unit 100 , and shares a reference with the above-described pipe 86 because of being the same.
  • the defibrating unit 20 performs defibration treatment on the small pieces (defibration object).
  • the defibrating unit 20 generates fibrous untangled fibers by subjecting the small pieces to defibration treatment.
  • the wording “defibration treatment” refers to untangling the small pieces in which the plurality of fibers is bonded into individual fibers.
  • the material that passes through the defibrating unit 20 is referred to as a “defibrated material”.
  • resin resin for causing a plurality of fibers to bond to one another
  • additives such as blur-preventing agents and paper strengthening agents, and colorants such as ink and toner are included in the “defibrated material” in addition to the untangled defibrated material fibers.
  • the wording “defibrated material” is at least a portion of the material passing through the defibrating unit 20 , and may be mixed with materials added after passing through the defibrating unit 20 .
  • the defibrating unit 20 isolates the additives and the colorants from the fibers.
  • the additives or colorants are discharged from the discharge port 22 along with the defibrated material.
  • the defibrating unit 20 performs the defibration treatment on the small pieces introduced from the introduction port 21 by a rotary blade.
  • the defibrating unit 20 performs defibrating with a dry method in air.
  • the configuration of the defibrating unit 20 is not limited, and possible examples include units that generate an airflow by a rotator rotating, and defibrate the defibration object with the airflow.
  • the defibrating unit 20 may include a mechanism that causes an airflow to be generated. In this case, it is possible for the defibrating unit 20 to suction the small pieces along with the airflow from an introduction port 21 , perform the defibration treatment, and transport the raw material to the discharge port 22 with the self generated airflow.
  • the defibrated material discharged from the discharge port 22 is introduced to the classifying unit 30 via the second conveyance unit 82 , as shown in FIG. 2 .
  • a mechanism that generates an air flow that introduces the small pieces to the introduction port 21 may be separately provided on the upstream or downstream side of the defibrating unit 20 .
  • the classifying unit 30 isolates and removes the additives or colorants from the defibrated material.
  • An airflow classifier is used as the classifying unit 30 .
  • the airflow classifier generates a swirling airflow, and performs isolation according to the size and density of the materials classified with centrifugal force, and it is possible to adjust the classification points through adjustment of the speed of the airflow and the centrifugal force.
  • a cyclone, an elbow jet, an eddy classifier and the like are used as the classifying unit 30 .
  • the cyclone it is possible for the cyclone to be favorably used as the classifying unit 30 because the structure is simple. Below, a case of using a cyclone as the classifying unit 30 will be described.
  • the classifying unit 30 includes at least an introduction port 31 , a lower discharge port 34 provided on the lower portion, and an upper discharge port 35 provided on the upper portion.
  • the airflow in which the defibrated material introduced from the introduction port 31 is carried is caused to move circularly, and, in so doing, centrifugal force is applied to the introduced defibrated material, and the material is isolated into a first classified material (untangled fibers) and a second classified material (additive or colorant) with a lower density than the first classified material.
  • the first classified material is used as the raw material of the sheet.
  • the second classified material is removed because of becoming a hindrance when forming the sheet. For example, the whiteness of the sheet when the sheet includes toner is lowered.
  • the strength of the sheet when materials smaller than the fibers are included is lowered.
  • the first classified material is discharged from the lower discharge port 34 and is introduced to the introduction port 46 of the screening unit 40 through the third conveyance unit 83 .
  • the second classified material is discharged to the outside of the classifying unit 30 from the upper discharge port 35 through the fourth conveyance unit 84 .
  • the resin is discharged to the outside by the classifying unit 30 , even if the resin is supplied by the composite supplying unit 150 , described later, it is possible to prevent the resin from becoming surplus with respect to the defibrated material.
  • classifying the first classified material and the second classified material by the classifying unit 30 is disclosed, isolation is not always reliably performed. Comparatively small or less dense materials from the first classified material may be discharged to the outside along with the second classified material. Comparatively high density materials or materials entangled with the first classified material from the second classified material may be introduced to the screening unit 40 along with the first classified material. In a case of a pulp sheet without waste paper as the raw material, because materials corresponding to the second classified material are not included, the classifying unit 30 may be not provided as the sheet manufacturing apparatus 1000 .
  • the screening unit 40 screens, in air, the defibrated material subjected to defibration treatment into “passing-through material” that passes through the screening unit 40 and “residue” that does not pass through.
  • a cylindrical sieve is used as the screening unit 40 .
  • the screening unit 40 includes an introduction port 46 and an discharge port 47 , as shown in FIG. 2 .
  • the screening unit 40 is a rotating sieve which large materials that are able to pass through the sieve pass through and large materials that are not able to pass through the first opening 42 do not pass through. It is possible for the screening unit 40 to screen the short fibers (passing-through material) according to a fixed length from the defibrated material subjected to the defibrating treatment by the sieve.
  • the residue not passing through the sieve of the screening unit 40 is discharged from the discharge port 47 and transported to the hopper 15 via the fifth conveyance unit 85 as a return flow path, and is returned again to the defibrating unit 20 , as shown in FIG. 1 .
  • the passing-through material passing through the sieve of the screening unit 40 is transported to the introduction port 66 of the distribution unit 60 via the sixth conveyance unit 86 (pipe 86 ) one received by the hopper 16 .
  • a supply port 151 for the composite (described later) that causes the fibers to bond to one another (defibrated materials to bond to one another) to be supplied is provided in the sixth conveyance unit 86 .
  • the composite supplying unit 150 supplied the composite in air from the supply port 151 to the sixth conveyance unit 86 (pipe 86 ). That is, the composite supplying unit 150 supplies the composite to the path in which the passing-through material of the screening unit 40 moves from the screening unit 40 to the distribution unit 60 (between the screening unit 40 and the distribution unit 60 ).
  • the composite supplying unit 150 is not particularly limited as long as it is able to supply the composite to the sixth conveyance unit 86 (pipe 86 ), and a screw feeder, circle feeder and the like are used. The composite supplied from the composite supplying unit 150 will be described later.
  • the mixing unit 100 is configured to include the composite supplying unit 150 and the sixth conveyance unit 86 (pipe 86 ).
  • the mixed material may be further mixed in the distribution unit 60 . Therefore, the distribution unit 60 may be a mixing unit 100 .
  • the distribution unit 60 refines the entangled passing-through material.
  • the distribution unit 60 may further refine the entangled composite in a case where the composite supplied from the composite supplying unit 150 is fibrous.
  • the distribution unit 60 evenly deposits the passing-through material and the composite on the deposition unit 72 , described later.
  • a sieve is used as the distribution unit 60 .
  • the distribution unit 60 is a rotating sieve that is able to rotate due to a motor (not shown).
  • the distribution unit 60 includes an introduction port 66 .
  • the difference in terms of configuration between the distribution unit 60 and the screening unit 40 is not including an discharge port (part corresponding to the discharge port 47 of the screening unit 40 ).
  • the upper limit of the size of the openings in the sieve of the distribution unit 60 is 5 mm. It is possible for materials to be refined and pass through without lumps in which the fibers are entangled with each other passing through by the size of the openings being 5 mm or less. Even if entangled fibers or the composite are present when mixed in the sixth conveyance unit 86 , they are refined when passing through the distribution unit 60 . Therefore, the fibers and the composite are deposited on the deposition unit 72 , described later, with a uniform thickness and density.
  • the wording “refine the entangled fibers” includes a case of completely refining the entangled fibers (case of all of the fibers reaching a refined state) and a case of refining a portion of the entangled fibers to the extent that the entangled fibers are able to pass through the sieve. The same applies to the meaning of the wording “refine the entangled composite”.
  • uniformly deposited refers to a state of the deposited material that is deposited being deposited at the same thickness and the same density. However, because the all of the deposited material is not necessarily manufactured as a sheet, the part that becomes the sheet may be uniform.
  • the defibrated material and the composite passing through the distribution unit 60 are deposited on the deposition unit 72 of the sheet forming unit 70 .
  • the sheet forming unit 70 includes the deposition unit 72 , the tension roller 74 , the heater roller 76 , the tension roller 77 , and the winding roller 78 .
  • the sheet forming unit 70 forms a sheet using the defibrated material and the composite passing through the distribution unit 60 .
  • the heater roller 76 and the tension roller 77 of the sheet forming unit 70 configure the above-described bonding unit 200 .
  • the deposition unit 72 of the sheet forming unit 70 receives and causes the defibrated material and the composite passing through the distribution unit 60 to be deposited.
  • the deposition unit 72 is positioned below the distribution unit 60 . Since the deposition unit 72 receives the defibrated material and the composite, for example, the deposition unit 72 is a mesh belt.
  • the mesh tensioned by the tension roller 74 is formed on the mesh belt.
  • the deposition unit 72 moves through the tension roller 74 rotating. A web with a uniform thickness is formed on the deposition unit 72 by the defibrated material and the composite from the distribution unit 60 continuously accumulating while the deposition unit 72 continuously moves.
  • the defibrated material and the composite deposited on the deposition unit 72 of the sheet forming unit 70 is heated and pressed by passing through the heater roller 76 according to the movement of the deposition unit 72 . Due to the heat, the resin functions as a bonding agent and causes the fibers to bond to each other, is thinned by the pressure, and the sheet S is formed. The surface may be further smoothened by being passed through a calendar roller, not shown. In the examples in the drawings, the sheet S is wound onto the winding roller 78 . Through the above, it is possible to manufacture the sheet S.
  • the fibers (fibrous material) used as a portion of the raw material is not particularly limited, and it is possible for a wide range of fiber materials to be used.
  • the fibers include natural fibers (animal or plant fibers) and chemical fibers (organic, inorganic or organic-inorganic composite fibers), and more specifically, examples include fibers made from cellulose, silk, wool, cotton, hemp, kenaf, flax, Ramie, jute, manila hemp, sisal hemp, softwood, and hardwood, and fibers made from rayon, lyocell, cupra, vinylon, acrylic, nylon, aramid, polyester, polyethylene, polypropylene, polyurethane, polyimide, carbon, glass, and metal and these may be used independently or mixed, as appropriate, or may be used as a regenerated fiber on which purification or the like is performed.
  • At least one of these fibers may be included as the raw material.
  • the fiber may be dried or may be contained or be impregnated with a liquid such as water or an organic solvent. Various surface treatments may be performed.
  • the material of the fibers may be a pure material, or may be a material that includes various components such as impurities, additives and other components.
  • the fibers used in the sheet manufacturing apparatus 1000 of the embodiment is string-like or ribbon-like, and may be one independent fiber or may be a plurality of fibers completely entangled with one another to form a string shape or a ribbon shape.
  • the fibrous material may be formed in a cotton-like form, or may be a form in which a plurality of fibers may be partially physically or chemically bonded to one another.
  • the structure of the fibers may be formed from one type of material, a so-called simple fiber, or the material may be continuously or step-wise modified from the center portion toward the outer peripheral portion. Examples of step-wise modifying the material from the central portion of the fiber toward the outer peripheral portion include a so-called core-sheath structure.
  • the fibers may be in a linear form, may be in a curved form, or may further be in a curled form overall.
  • the shape of the cross-sectional of the fibers is not particularly limited, and may be a circle, an ellipse, a polygon, or a combination thereof.
  • the fibers may also be fibrillated fibers.
  • the average diameter in a case where the cross-section is not a circle, the diameter of a circle when a circle having the greatest length from the lengths in a direction perpendicular to the length direction or equivalent to the area of the cross-section (equivalent circle diameter) is assumed) thereof is 1 ⁇ m or more to 1000 ⁇ m or less, 2 ⁇ m or more to 500 ⁇ m or less is preferable, and 3 ⁇ m or more to 200 ⁇ m or less is more preferable.
  • the length of the fibers used by the sheet manufacturing apparatus 1000 of the embodiment is not particularly limited, in one independent fiber, the length along the length direction of the fiber is 1 ⁇ m or more to 5 mm or less, 2 ⁇ m or more to 3 mm or less is preferable, and 3 ⁇ m or more to 2 mm or less is more preferable.
  • the length of the fibers is short, although the strength of the sheets may be insufficient because the fibers do not easily bond with the composite, it is possible to obtain a sufficiently strong sheet as long as the length is within the above ranges.
  • the length along the length direction of the fibers may be the distance (length of the fibers) between both ends when both ends of one independent fiber is stretched so as not to break, as necessary, and placed in a substantially linear state in this state.
  • the average length of the fibers, as the length-length-weighted mean fiber length is 20 ⁇ m or more to 3600 ⁇ m or less, 200 ⁇ m or more to 2700 ⁇ m or less is preferable, and 300 ⁇ m or more to 2300 ⁇ m or less is more preferable.
  • the length of the fibers may have variations (distribution), and in a case where a normal distribution in a distribution obtained with an n of 100 or more is assumed, the ⁇ for the length of one independent fiber may be 1 ⁇ m or more to 1100 ⁇ m or less, preferable 1 ⁇ m or more to 900 ⁇ m or less, and more preferably 1 ⁇ m or more to 600 ⁇ m or less.
  • the wording “cotton-like” indicates a state of having a three-dimensional bulky external shape due to one long fiber or a plurality of fibers being entangled with one another or coming partially into contact with one another. That is, cotton-like indicates a solid shape formed by entanglement or partial contact of the fibers, and a gas partially encapsulated in the shape. The phrasing cotton-like is used regardless of whether or not the plurality of fibers are bonded to one another.
  • the composite used as a portion of the raw material integrally includes a resin and a coloring material.
  • the state of the composite integrally including the resin and the coloring material refers to a state where the resin or coloring material from the composite do not easily break part (not easily drop off) in either or both of the sheet manufacturing apparatus 1000 or the manufactured sheet S. That is, the state of the composite integrally including the resin and the coloring material indicates a state in which the coloring materials are bonded to one another by the resin, a state where the coloring material is structurally (mechanically) fixed to the resin, a state where the resin and the coloring material are coagulated due to electrostatic force or Van der Waal's forces, and a state in which the resin and the coloring material are chemically bonded.
  • the state of the composite integrally including the resin and the coloring material may also be a state where the coloring material is encapsulated in the resin or may be a state where the coloring material is attached to the resin, and includes a state where both states are present at the same time.
  • the same also applies to a case of integrally including the resin and the coagulation inhibitor, described later.
  • FIG. 4 schematically shows several states of cross-sections of the composite in which the resin and the coloring materials are integrally included.
  • Examples of the specific form of the composite integrally including the resin and the coloring material include a composite 3 having a structure in which a single or a plurality of coloring materials 2 is dispersed and encapsulated inside the resin 1 as shown in FIGS. 4( a ) to 4( c ) , and a composite 3 in which a single or a plurality of coloring materials 2 is attached to the surface of the resin 1 as shown in FIG. 4( d ) .
  • an aggregate (powder) of such a composite 3 as the composite.
  • FIG. 4( a ) shows an example of the composite 3 having a structure in which a plurality of coloring materials 2 (drawn as particles) is dispersed in the resin that configures the composite 3 .
  • a composite 3 forms a so-called sea-island structure with the resin 1 dispersed as a matrix and the coloring material 2 as the domain.
  • the coloring material 2 because of the state in which the coloring material 2 is surrounded by the resin 1 , it is difficult for the coloring material 2 to pass through the resin part (matrix) and be separate to outside the resin 1 . Therefore, when various processes are received or when the sheet is formed in the sheet manufacturing apparatus 1000 , the coloring material 2 is in a state of not easily dropping off from the resin part.
  • the coloring material 2 may come in contact with itself or the resin 1 may be present between the coloring material 2 in the dispersion state the coloring material 2 inside the composite 3 in this case.
  • dispersion may be biased toward one side.
  • the coloring material 2 may be only on the right side or the left side.
  • the coloring material 2 may be arranged in the center portion of the resin 1 as in FIG. 4( b ) or the coloring material 2 may be arranged in a part near the surface of the resin 1 as in FIG. 4( c ) .
  • the resin 1 may include a mother particle 4 in the vicinity of the center and a shell 5 on the periphery thereof.
  • the mother particle 4 and the shell 5 may be the same type of resin as one another or may be differing types of resin.
  • the example shown in FIG. 4( d ) is the composite 3 with a form in which the coloring material 2 is embedded in the vicinity of the surface of particles formed from the resin 1 .
  • the coloring material 2 is exposed in the surface of the composite 3 , it is possible to attain a state in which the composite 3 does not easily fall off from the composite 3 through bonding (chemical or mechanical bonding) with the resin 1 or mechanical fixing due to the resin 1 , and to suitably use such a composite 3 in the sheet manufacturing apparatus 1000 of the embodiment as the composite integrally including the resin 1 and the coloring material 2 .
  • the coloring material 2 may be present not only in the surface of the resin 1 , but also on the interior.
  • the coloring material includes a function making the color of the sheet S manufactured by the sheet manufacturing apparatus 1000 of the embodiment into a predetermined color. It is possible for a dye or a pigment to be used as the coloring material, and in a case of integrally including the resin in the composite, it is preferable to use a pigment from the viewpoint of obtaining a better hiding power or chromagenicity.
  • the pigment along with the color and type thereof is no particularly limited, and it is possible to use various colors (such as white, blue, red, yellow, cyan, magenta, yellow, black, and special colors (pearl, metallic gloss)) of pigment used in ordinary inks.
  • the pigment may be an inorganic pigment or may be an organic pigment. It is possible to use known pigments disclosed in Japanese Unexamined Patent Application Publication No. 2012-87309 or Japanese Unexamined Patent Application Publication No. 2004-250559 as the pigment.
  • White pigments and the like such as zinc oxide, titanium oxide, antimony white, zinc sulfide, grey, silica, white carbon, talc, alumina white may be used. These pigments may be used either independently or mixed, as appropriate.
  • a pigment formed from a powder that includes particles (pigment particles) with titanium oxide as a main component from the above-described examples on the point of ease of increasing the whiteness in the manufactured sheet S from the magnitude of the refractive index of the titanium oxide with a small blending amount.
  • the phrasing “coloring material” is used to signify a material for coloring.
  • this includes the meaning of a powder in which a plurality of single particles (pigment particles) thereof are aggregated.
  • the wording “single particle (pigment particle)” refers to particles which are difficult to make smaller than the above by an ordinary crushing unit.
  • the single particle (pigment particle) may be fine crystals of titanium oxide as the primary particles, and a plurality of primary particles may be aggregated. The coagulation between primary particles in this case may aggregate when forming chemical bonds or twin crystals, a mechanical crushing is frequently difficult.
  • the structure of one pigment particle may be the particle itself or a bonded body of primary particles being the primary particle.
  • the method of integrally including the resin and the coloring material to the composite is not particularly limited even in a case of adopting the structure of nay of the above-described FIGS. 4( a ) to 4( d ) , and it is possible to use, as appropriate, known methods.
  • An example of the method of obtaining the composite of the form is described in the above-described FIG. 2 .
  • Examples of the method of obtaining the composite of the form in FIG. 4( a ) include a melt-kneading method of heating a predetermined resin to the temperature of the softening point or higher and kneading with the pigment (coloring material) and a method of mixing the resin with the pigment while being dissolved or swelled with water or a solvent.
  • Examples of devices usable with these methods include a kneader, a Banbury mixer, a single screw extruder, a multi-screw extruder, a twin roll, a triple roll, a continuous kneader, and a continuous twin roll.
  • the pigment may be subjected to a hydrophobization treatment in order for the pigment to be more uniformly dispersed in the resin.
  • a coagulated mass of the pigment is present before the melt-kneading, it is effective to disperse the pigment uniformly in the resin by crushing the coagulated mass with a mixer or the like.
  • the composite by pelletizing and crushing with an appropriate method after kneading. It is possible to perform the crushing using a known crushing method. Examples of the crushing machine used include a hammer mill, a pin mill, a cutter mill, a pulverizer, a turbo mill, a disk mill, a screen mill, and a jet mill, and it is possible to obtain the resin particles by combining these, as appropriate.
  • the process of crushing may be performed stepwise, such as finely crushing to a target particle diameter after first roughly crushing so that the particle diameter becomes approximately 1 mm. Even in such a case, it is possible to use the appropriate devices given above in each step. It is further possible to use a freeze-crushing method for improving the crushing efficiency of the composite.
  • the composite obtained in this way includes various sizes, and in order to make the composite into the target size, the composite may be classified using a known classifying device. If the above methods are adopted, it is possible to obtain a composite with the structure as shown in FIG. 4( a ) .
  • the content of the coloring material in the composite is greater than 0% by mass to 50% by mass or less.
  • the content of the coloring material in the composite is greater than 0 parts by weight to 100 parts by weight or less when expressed in terms of parts by weight (external addition: addition amount of the coloring material to the resin).
  • the content of the coloring material in the composite is, from the viewpoints of obtaining sufficiently strong coloring of the manufactured sheet, of suppressing dropping off of the coloring material from the composite, and of stability (suppressing brittle collapse of the composite due to impact or the like) of the shape of the composite, 1% by mass or more to 50% by mass or less, and 2% by mass or more to 30% by mass or less is more preferable, and 3% by mass or more to 20% by mass or less is still more preferable.
  • a coagulation inhibitor may be blended into the composite or the powder that includes the composite.
  • the coagulation inhibitor in a case of being blended in the composite, has a function of making the composite integrally including the resin and the coloring material not coagulate to each other compared to a case of not being blended.
  • various coagulation inhibitors can be used, in the sheet manufacturing apparatus 1000 of the embodiment, it is preferable to use a type (may be coated (covered) or the like) arranged in the surface of the composite because little to no water is used.
  • the composite may not integrally include the coloring material or the coloring material may not be used.
  • the composite used as a portion of the raw material integrally includes a resin and a coagulation inhibitor.
  • the coagulation inhibitor examples include fine particles formed from an inorganic material, and it is possible to obtain an extremely superior coagulation inhibition effect by blending the particles in the surface of the composite as in FIG. 4( d ) . Therefore, reference 2 in FIG. 4( d ) may be the coagulation inhibitor.
  • coagulation indicates a state where the same or different types of substance are present in physical contact due to electrostatic force or Van der Waal's forces.
  • all of the substances that configure the aggregation being arranged while discrete is not necessarily indicated.
  • a state in which a portion of the substance that configures the aggregation is coagulated is also included in the state of not being coagulated, and the even if the content of such a coagulated substance is approximately 10% by mass or less of the entire aggregation, and preferably approximately 5% by mass or less, this state is included in the “state of not being coagulated” in the aggregate of the plurality of substances.
  • the material of the coagulation inhibitor include silica, titanium oxide, aluminum oxide, zinc oxide, cerium oxide, magnesium oxide, zirconium oxide, strontium titanate, barium titanate, and calcium carbonate.
  • the materials differ in that the particle diameter of the coagulation inhibitor is smaller than the particle diameter of the coloring material. Therefore, therefore, because the coagulation inhibitor does not greatly influence the tone of the manufactured sheet, in the specification the coagulation inhibitor can be distinguished from the above-described coloring material.
  • the coagulation inhibitor when regulating the tone of the sheet, even if the particle diameter of the coagulation inhibitor is small, because a slight effect of light scattering or the like arises, it is preferable for such an effect to be taken into consideration.
  • the average particle diameter (number average particle diameter) of the coagulation inhibitor particles although not particularly limited is 0.001 to 1 ⁇ m, and more preferably 0.008 to 0.6 ⁇ m.
  • the coagulation inhibitor particles being the primary particles is normal in light of being close to the category of so-called nanoparticles, and the particle diameter being small, a plurality of primary particles may be bonded to form a higher order particle. If the particle diameter of the coagulation inhibitor primary particles is within the above ranges, it is possible to favorable coat the surface of the composite, and possible to impart a sufficient coagulation inhibition effect.
  • the coagulation inhibitor is arranged in the surface of the composite, the coagulation inhibitor is present between different composites and it is possible to suppress coagulation.
  • the composite and the coagulation inhibitor are separate bodies, because the coagulation inhibitor is not limited to being present between the different composites, and there as cases where the composites coagulate with each other.
  • the addition amount in the case of adding the coagulation inhibitor to the composite is made 0.1 parts by weight or more to 5 parts by weight or less with respect to 100 parts by weight of the composite, and from the viewpoint of either or both of increasing the effect and suppressing dropping off the of the coagulation inhibitor from the manufactured sheet, 0.2 parts by weight or more to 4 parts by weight or less with respect to 100 parts by weight of the composite is preferable, and 0.5 parts by weight or more to 3 parts by weight or less is more preferable.
  • the method of arranging (coating) the coagulation inhibitor in the surface of the composite is not particularly limited, and the coagulation inhibitor may be arranged along with the resin and the coloring materials when forming the composite by melt-kneading or the like as described above. However, if done in this way, because the coagulation inhibitor is largely arranged inside the composite, the coagulation inhibition effect with respect to the addition amount of the coagulation inhibitor is reduced. It is more preferable that the coagulation inhibitor is arranged as much as possible in the surface of the composite based on the coagulation inhibiting mechanism.
  • examples of the form for arranging the coagulation inhibitor in the surface of the composite include coating and covering, the entire surface of the composite is not necessarily coated. Although the coverage ratio may exceed 100%, when reaching approximately 300% or more, because there are cases where the action of bonding the composite and the fibers is impeded, an appropriate coverage ratio is selected according to the situation.
  • the proportion coved by the coagulation inhibitor in the composite surface is 20% or more to 100% or less, it is possible to obtain a sufficient charging effect. It is possible to adjust the coverage ratio by incorporating in a device such as an FM mixer. If the specific surface area of the coagulation inhibitor and the composite is known, it is possible to perform regulation by the mass (weight) of each component when incorporated. It is possible to measure the coverage ratio with various electron microscopes. In a case where the coagulation inhibitor is arranged in a form of being not easily detached from the composite, it is possible for the coagulation inhibitor to be integrally included in the composite.
  • the coagulation inhibitor When the coagulation inhibitor is arranged in the composite, because coagulation of the composite is made extremely difficult to occur, it is possible for the composite and the fibrous material to be more easily mixed together in the mixing unit 100 . That is, when the coagulation inhibitor is arranged in the composite, it is possible for the composite to be quickly diffused in a space and form an extremely uniform mixed material.
  • Examples of the reason it is possible for the composite and the fibers to be extremely favorably mixed together due to agitation by air currents or a mixer due to the coagulation inhibitor include that the composite tends to be easier to charge with static electricity in a case where the coagulation inhibitor is arranged in the surface of the composite, and coagulation of the composite due to the static electricity is suppressed.
  • the composite attached to the fibers by to the static electricity becomes less easily detached from the fibers even in cases where a mechanical impact or the like occurs.
  • the composite may include other components in addition to the above-described resin, coloring agent, and coagulation inhibitor.
  • the other components include organic solvents, surfactants, preservative and fungicide agents, antioxidants, ultraviolet absorbing agents, and oxygen absorbing agents.
  • the type of resin that is a component of the composite of the coloring agent or the coagulation inhibitor may be either a natural resin or a synthetic resin, and may be either a thermoplastic resin or a heat-curable resin.
  • the resin that configures the composite is preferably a solid at room temperature, and is preferably a thermoplastic resin in consideration of bonding the fibers due to heat in the bonding unit 200 .
  • Examples of the natural resin include rosin, dammar, mastic, copal, amber, shellac, dragon's blood palm resin, sandarac, and colophony, and these resins may be independent or mixed, as appropriate, and may be modified as appropriate.
  • heat-curable resin from the synthetic resins examples include heat-curable resins such as phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, allkyd resins, polyurethane, and heat-curable polyimide resins.
  • thermoplastic resin from the synthetic resins examples include AS resins, ABS resins, polypropylene, polyethylene, polyvinyl chloride, polystyrene, acrylic resins, polyester resins, polyethylene terephthalate, polyphenylene ether, polybutylene terephthalate, nylon, polyamide, polycarbonate, polyacetal, polyphenylene sulfide, and polyetherether ketone. These resins may be used independently or mixed, as appropriate.
  • Copolymerization or modification may be performed, and examples of such systems of resin include styrene resins, acrylic resins, styrene-acrylic copolymer resins, olefin based, polyvinyl chloride resins, polyester resins, polyamide resins, polyurethane resins, polyvinyl alcohol resins, vinyl ether resins, N-vinyl resins, and styrene-butadiene resins.
  • styrene resins acrylic resins, styrene-acrylic copolymer resins, olefin based, polyvinyl chloride resins, polyester resins, polyamide resins, polyurethane resins, polyvinyl alcohol resins, vinyl ether resins, N-vinyl resins, and styrene-butadiene resins.
  • the external shape of the composite is not particularly limited, and may be a shape such as disk-shaped and an irregular shape. However, it is more preferable that the shape of the composite approach spherical as much as possible because of the ease of being arranged between the fibers in the mixing unit 100 .
  • the volume average particle diameter d of the crushed composite influences the dispersion situation of the composite in the formed sheet S.
  • the amount of the composite arranged in the sheet is fixed, although the bonding force between the fibers in parts where the composite is arranged increases when the volume average particle diameter d of the composite is large, because the dispersion (distribution) of the composite in the sheet S surface is coarse and parts were the bonding force between the fibers are possible, the strength as a sheet S lowers.
  • the amount of the composite arranged in the sheet S is fixed, because the composite is easily uniformly dispersed (distributed) in the sheet S surface when the volume average particle diameter d of the composite is small, the strength as a sheet S also improves.
  • volume average particle diameter d depends on the blending amount of the composite in the sheet S, in a case where the blending amount is 5% by mass or more to 70% by mass or less, it is preferable that the volume average particle diameter d is 1 ⁇ m or more to 100 ⁇ m or less, and 5 ⁇ m or more to 35 ⁇ m or less is more preferable.
  • the size (volume average particle diameter d) of the composite is able to be adjusted according to the size (average diameter D) of the fibers that configure the fibrous material.
  • the size (volume average particle diameter d) of the composite from the viewpoint of more uniformly mixing the fibers and the composite in the mixing unit 100 , it is preferable that the volume average particle diameter d of the composite is smaller than the size (average diameter D) of the particles that configure the fibrous material.
  • the mixing ratio thereof is regulated, as appropriate, according to the strength, usage, or the like of the manufactured sheet S.
  • the proportion of the composite to the fibers is 5% by mass or more to 70% by mass or less, and from the viewpoints of obtaining favorable mixing in the mixing unit 100 and making the composite less easily influenced by gravity in a case where the mixture is formed in a sheet-shape, 5% by mass or more to 50% by mass of less is preferable.
  • the sheet manufacturing apparatus 1000 of the embodiment even in a state (dry type) with little liquid, it is possible to favorably perform mixing of the fibers and the composite in the mixing unit 100 .
  • the composite integrally including a resin and a coloring material is bonded to the fibers in the bonding unit 200 . Since the coloring material is easily held by the resin that bonds the fibers to each other, it is possible to manufacture a sheet in which the coloring material is not easily detached by the composite integrally including the resin and the coloring material.
  • the coagulation inhibitor is integrated with the resin to make the composite, it is possible to remarkable reduce coagulation of the composites to each other.
  • the composites coagulate with each other, parts with little composite are possible by the composite gathering in one portion. In the parts with little composite, the bonding force between the fibers becomes low, and the strength as a sheet S is insufficient.
  • the composite it is possible for the composite to be uniformly dispersed, to create a sheet S with a favorable strength.
  • the coloring material is also uniformly dispersed, and it is possible to create a sheet S in which the uniformity of the tone in the sheet S is favorable (color unevenness is suppressed).
  • the composite integrally including the fibrous material and the coagulation inhibitor it is possible for the composite integrally including the fibrous material and the coagulation inhibitor to be uniformly mixed by a dry method, without using moist pulp molding.
  • the dispersion of the resin also becomes favorable, and manufacturing sheet S with excellent strength is possible.
  • a sheet S with favorable tone can be manufactured. Since the composite integrally including either or both of the coloring material and the coagulation inhibitor and the resin is uniformly mixed by being mixed with the resin, the effect is exhibited even just by mixing.
  • a sheet S can be manufactured with a method using little to no water, and plumbing facilities and the like at the manufacturing facility are unnecessary. According to the sheet manufacturing apparatus 1000 of the embodiment, achieving size reductions is particularly easy because the water using parts become unnecessary. Therefore, it is possible to increase degree of freedom in the installation location. According to the sheet manufacturing apparatus 1000 of the embodiment, the energy such as electric power for dewatering and drying is unnecessary, and manufacturing a sheet S in a short time not obtained in the pulp molding method while achieving in lowering costs.
  • the sheet manufacturing method of the embodiment includes a step of mixing together a composite integrally including fibers and a resin and a coloring material or a resin and a coagulation inhibitor, and a bonding the fibers and the composite together. Because the fibers, the resin, the coloring material, and the composite are the same as those described in the above-described sheet manufacturing apparatus item, detailed description thereof will not be provided.
  • the sheet manufacturing method of the embodiment may include at least one step selected from a group composed of a step for cutting a pulp sheet or waste paper as a raw material in air, a defibrating step of disentangling the raw material in air into a fibrous form, a classifying step of classifying, in air, impurities (toner or paper strengthening agent) and fibers (short fibers) shortened by defibration from the defibrated material that is defibrated, a screening step of screening, in air, long fibers and undefibrated pieces that are insufficiently defibrated from the defibrated material, a dispersing step of causing the mixture to descend while being dispersed in air, a forming step of forming the descended mixture in a web shape or the like while being deposited, a drying step of causing the sheet to be dried as necessary, a winding step of winding the formed sheet into a roll shape, a cutting step of cutting the formed sheet, and a packaging step of
  • the sheet S manufactured by the sheet manufacturing apparatus 1000 or the sheet manufacturing method of the embodiment mainly indicates a sheet in which at least the above-described fibers are the raw material and formed into a sheet form.
  • a sheet form there is no limitation to a sheet form, and the shape may be a board form, web form, or a shape having concavities and convexities.
  • the sheets in the specification can be classified into paper and non-woven fabric.
  • Paper includes forms in which pulp or waste paper as a raw material is formed in a sheet shape, and includes recording paper for the purpose of writing or printing, wallpaper, packaging paper, colored paper, image paper, Kent paper and the like.
  • Non-woven fabric is a product thicker than paper or with low strength, and includes ordinary non-woven fabrics, fiber boards, tissue papers, kitchen papers, cleaners, filters, liquid absorbing materials, sound absorbers, shock absorbers, mats, and the like.
  • the accommodation container of the embodiment accommodates the above-described composite in which the resin and the coagulation inhibitor are integrated, used mixed with the fibers.
  • the composite of the embodiment is supplied to the mixing unit 100 according to the opening and closing of a feeder or valve.
  • the composite of the embodiment is supplied in a powdered state in appearance. Therefore, it is possible to configure the apparatus so that the composite is directly supplied to the mixing unit 100 through a pipe or the like after being manufactured. However, according to the installation location of the apparatus, it is thought that the composite is carried along a flow path as a commodity, and there are cases where transfer or storage is performed after the composite is manufactured.
  • the accommodation container of the embodiment includes an accommodation chamber that accommodates the composite, and it is possible for the composite to be accommodated in the accommodation chamber. That is, it is possible for the accommodation container of the embodiment to be a composite cartridge, and it is possible to easily transport and store the composite.
  • the shape of the accommodation container is not particularly limited, and it is possible for the shape to be made a cartridge shape suitable to the sheet manufacturing apparatus 1000 . It is possible to form the accommodation container with an ordinary polymer material.
  • the accommodation container may also be a box-like robust form, or may be a film- (bag) like flexible form. It is preferable that the material that configures the accommodation container is configured from a material with a low glass-transition temperature or melting point compared to the material of the accommodated composite.
  • the accommodation chamber that accommodates the container is not particularly limited as long as it is able accommodate and hold the composite. It is possible for the accommodation chamber to be formed from a film, a molded body, or the like. In a case where the accommodation chamber is formed by a film, the accommodation container may be formed including a molded body (housing) so as to accommodate the film that forms the accommodation chamber. The accommodation chamber may be formed by a comparatively robust molded body.
  • the film or molded body that forms the accommodation chamber may be configured from a polymer, a metal deposition film, or the like, and may have a multilayer structure.
  • the accommodation container is formed by a plurality of members such as a film or molded body, fused parts or bonded parts may be formed.
  • the accommodated composite (powder) is influenced, such as deterioration, due to contact with the atmosphere, it is preferable that the film or molded body is formed from a material with little gas permeability. It is preferable that the material of the part that contacts the accommodated composite from the materials of the film and molded body that configure the accommodation chamber is stable with respect to the composite.
  • the shape and volume of the accommodation chamber is not particularly limited. Although the composite is accommodated in the accommodation chamber, an inactive solid or gas may be accommodated in contrast thereto. The volume of the composite accommodated in the accommodation chamber is also not particularly limited.
  • the accommodation chamber may include a flow port that communicates between the interior of the accommodation chamber and the exterior of the accommodation container, and is able to remove the composite to the outside of the accommodation container.
  • the accommodation chamber may have another flow path other than the flow port formed therein.
  • the other flow path may be configured by a release valve or the like.
  • providing the release valve in the accommodation chamber although the position at which the release valve is arranged is not particularly limited, there are cases where providing the release valve is preferable because the composite is not easily discharged when the pressure is released to the atmosphere in cases where pressure and the like is generated in the accommodation chamber when arranged on the opposite side to the direction in which gravity acts in the normal posture when transferred, transported, and used.
  • the sheet manufacturing apparatus and sheet manufacturing method of the embodiment use no or only a small amount of water, it is possible to manufacture the sheet while adding water, as appropriate, with the object of adjusting the moisture or the like, through spraying or the like as necessary.
  • the phrasing “uniform” indicates, in a case of uniform dispersion or mixing, the relative positions where one component is present with respect to the other component are even in the entire system or are the same or substantially equal in each part of the system to one another in a substance able to define a component with two types or more or two phases or more. Uniformity of coloring or uniformity of tone indicates an even concentration without tinting of the color when the sheet is seen in plan view.
  • the composite is uniformly dispersed and coloring uniformity improves by integrating the coagulation inhibitor and the resin, and is not necessarily limited to being even. Resin that is not integrated is also produced in the step of integrally manufacturing the coagulation inhibitor and the resin.
  • phrasing such as “uniform”, “same”, “even intervals” or the like is used to indicate that density, distance, measurement or the like are the same. Although it is desirable that these are equal, because being made completely equal is difficult, the wording includes being shifted by the cumulative errors or variations without the values being equal.
  • polyester resin manufactured by Toyobo Co., Ltd, brand name “Vylon 220”, glass-transition temperature: 54° C., softening point: 96° C.
  • blue copper phthalocyanine manufactured by Toyo Color Co., Ltd., brand name Lionol Blue FG-7330
  • a high speed mixer manufactured by Nippon Coke & Engineering Co., Ltd, brand name “FM-type mixer FM-10C”
  • the resin-pigment mixture was supplied from the hopper of a twin screw kneading extruder (manufactured by Toshiba Machine Co., Ltd., trade name “TEM-26SS”), melt-kneading was performed, and the result was pelletized to obtain tablets with a diameter of approximately 3 mm. Since there is no phenomenon of the resin detaching from the time of pelletizing, it is determined that the resin and the coloring material are integrated.
  • TEM-26SS twin screw kneading extruder
  • crushed particles with a diameter of 1 mm or less were obtained with a hammer mill (manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”).
  • the crushed particles were further crushed by a jet mill (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “PJM-80SP”), and a composite with a maximum particle diameter or 40 ⁇ m or less was obtained.
  • the crushed material of the composite was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and the volume average particle diameter d of the composite was made 10 ⁇ m.
  • Powdered cellulose (Nippon Paper Industries Co., Ltd., brand name “KC FLOCK W-50S”) was used.
  • the average diameter of the fibers was 19 ⁇ m (below, these fibers are denoted as X).
  • the composite material was carried on a fluorine coated aluminum plate with the same diameter, pressurized and compressed. After the formed composite material was held for 60 seconds while set on a hot press in a state of being interposed by the aluminum disk, the composite material was drawn out from the pressing machine while the pressure was released and left until reaching room temperature. Thereafter, the sheet (paper) was obtained by removing the hot formed composite material from the aluminum disk.
  • Example 2 Up to obtaining the composite with a maximum particle diameter or 40 ⁇ m was performed similarly to Example 1.
  • the composite was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and the volume average particle diameter d of the composite was made 20 ⁇ m.
  • MDS-3 airflow classifier
  • Kraft paper (manufactured by Oji Materia Co., Ltd., brand name “OK Unbleached Kraft”) was cut into paper pieces with a width of 10 mm and a length of 30 mm and linear fibers were obtained by processing these in a dry type pulp defibrating machine (manufactured by Kumagai Riki Kogyo Co., Ltd., No. 2535) at room temperature.
  • the linear fibers were spread on a metal sieve with an opening size of 5 mm, and used with the undefibrated material mixed into the fibers removed.
  • the fiber diameter of the fibers was 33 ⁇ m (below, these fibers are denoted as Y).
  • the composite material was carried on a fluorine coated aluminum plate with the same diameter, pressurized and compressed. After the mixed material was held for 60 seconds while set on a hot press in a state of being interposed by the aluminum disk, the composite material was drawn out from the pressing machine while the pressure was released and left until reaching room temperature. Thereafter, the sheet (paper) was obtained by removing the hot formed composite material from the aluminum disk.
  • Example 2 After the pellets obtained in similarly to Example 1 were cooled to the vicinity of room temperature, crushing was performed until particles with a diameter of 1 mm or less were obtained with a hammer mill (manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”). The crushed particles were further crushed by a jet mill (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “PJM-80SP”), and a composite with a maximum particle diameter or 60 ⁇ m or less was obtained. The composite was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and a composite in which the resin and the coloring material are integrated with volume average particle diameter d of 35 ⁇ m was obtained.
  • a hammer mill manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”.
  • the crushed particles were further crushed by a jet mill (manufactured
  • Example 2 After the pellets obtained similarly to Example 1 were cooled to the vicinity of room temperature, crushing was performed until particles with a diameter of 1 mm or less were obtained with a hammer mill (manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”). The crushed particles were further crushed by a jet mill (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “PJM-80SP”), and a composite with a maximum particle diameter or 25 ⁇ m or less was obtained. The composite was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and a composite in which the resin and the coloring material are integrated with volume average particle diameter d of 5 ⁇ m was obtained.
  • a hammer mill manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”.
  • the crushed particles were further crushed by a jet mill (manufactured by
  • the composite was not used, and resin particles not integrally including the coloring material were used.
  • 2000 parts (pellets) of polyester resin manufactured by Toyobo Co., Ltd, brand name “Vylon 220” were roughly crushed until the diameter reached a size of 1 mm or less with a hammer mill (manufactured by Dalton Co., Ltd, brand name “Labomill LM-05”).
  • the resin particle powder was further crushed by a jet mill (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “PJM-80SP”), and a particulate with a maximum particle diameter or 40 ⁇ m or less was obtained.
  • the obtained particulate was spread on a metal sieve with 100 ⁇ m openings and foreign materials and coarse particles were removed.
  • the particulate was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and a resin particles with volume average particle diameter d of 10 ⁇ m was obtained.
  • MDS-3 airflow classifier
  • Example 2 After the pellets obtained similarly to Example 1 were cooled to the vicinity of room temperature, crushing was performed until particles with a diameter of 1 mm or less were obtained with a hammer mill (manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”). The powder (particulate) was further crushed by a jet mill (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “PJM-80SP”), and a composite with a maximum particle diameter or 70 ⁇ m or less was obtained. The obtained composite was spread on a metal sieve with 100 ⁇ m openings and foreign materials and coarse particles were removed. The composite was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and a composite in which the resin and the coloring material are integrated with volume average particle diameter d of 50 ⁇ m was obtained.
  • MDS-3 airflow classifier
  • Example 2 After the pellets obtained similarly to Example 1 were cooled to the vicinity of room temperature, the pellets were introduced to a hammer mill (manufactured by Dalton Co., Ltd., brand name “Labomill LM-05”) and crushing was performed until particles with a diameter of 1 mm or less were obtained. The crushed product was further crushed by a dry-type crusher (manufactured by Sugino Machine Limited, brand name “Dry Burst DB-180W”), and a composite (particulate) with a maximum particle diameter of 130 ⁇ m or less was obtained. The obtained composite was spread on a metal sieve with 400 ⁇ m openings and foreign materials and coarse particles were removed.
  • a dry-type crusher manufactured by Sugino Machine Limited, brand name “Dry Burst DB-180W”
  • the composite was classified by an airflow classifier (manufactured by Nippon Pneumatic Mfg. Co., Ltd., brand name “MDS-3”), and a composite (with the resin and the coloring material integrated) with volume average particle diameter d of 80 ⁇ m was obtained.
  • MDS-3 airflow classifier
  • Reference Example 4 was carried out similarly to Reference Example 2, and a particulate with a volume average particle diameter d of 50 ⁇ m.
  • the value of d/D and whether or not the relationship of d ⁇ D is satisfied with a case where satisfied as “ ⁇ ”, a case where not satisfied as “x”, and a case where satisfied in a range of ⁇ 10% of the value as “ ⁇ ” are disclosed in Table 1.
  • test piece (total length 75 mm) of 1BA of JISK 7162 was cut out from the sheet (paper) obtained with the above-described method, and tensile testing was carried out.
  • JISK 7161 testing was performed in an environment of a 23° C. room temperature and a relative humidity of 50%.
  • the strength (MPa) value of the breaking point in each example is disclosed in Table 1.
  • a test piece with a width of 15 mm and a length of 120 mm was cut out from a sheet (paper) obtained by the above methods, and the optical reflection density at positions of 20 mm, 40 mm, 60 mm, 80 mm, and 100 mm from the end portion was measured with a spectral densitometer (manufactured by Xrite Incorporated, brand name “X-Rite 528”) in cyan mode.
  • a spectral densitometer manufactured by Xrite Incorporated, brand name “X-Rite 528”
  • the coloring uniformity was favorable for Examples 1 to 6 using the composite integrally including the resin and the coagulation inhibitor. This is because coagulation of the composite is suppressed, and the composite is uniformly dispersed by using the composite in which the resin is integrated by being coating with the coagulation inhibitor. In light of this, it can be said that when the resin and the coagulation inhibitor are integrated, an effect is exhibited in which the resin is uniformly dispersed.
  • the tensile strength of the sheet was more favorable for Examples 1 to 6 using the composite integrally including the resin and the coagulation inhibitor than in the Reference Example 2 in which the resin and the coagulation inhibitor are separate bodies. This is because, although the coagulation inhibition effect is present in a case where the resin and the coagulation inhibitor are separate bodies and in a case where the coagulation inhibitor is arranged between the resin, the resin coagulates with the resin in a case where there is no coagulation inhibitor between the resin, and the resin is not uniformly dispersed. Therefore, locations where the fibers are not bonded to the fibers by the resin, and the strength as a sheet is lowered. Meanwhile, the resin is uniformly dispersed when the resin and the coagulation inhibitor are integrated, favorable values are achieved without lowering the strength as a sheet.
  • the obtained sheet has the characteristics of superior uniformity of coloring (uniformity of tone) after formation and superior tensile strength by forming the sheet using the mixed material in which the composite integrally including either or both of the coloring agent and the coagulation inhibitor with the resin and the fibers.
  • the mixed material in which the composite integrally including either or both of the coloring agent and the coagulation inhibitor with the resin and the fibers.
  • the invention includes configurations which are substantially the same as the configurations described in the embodiments (for example, configurations having the same function, method, and results, or configurations having the same purpose and effect).
  • the invention includes configurations in which non-essential parts of the configurations described in the embodiments are replaced.
  • the invention includes configurations exhibiting the same actions and effects as the configurations described in the embodiments or configurations capable of achieving the same object.
  • the invention includes configurations in which known techniques were added to the configurations described in the embodiments.
  • the invention is suitable to a sheet in which a tensile strength of 39 MPa or more is demanded.
  • a tensile strength of 39 MPa or more is demanded.
  • a higher value of tensile strength is demanded for a paper than for a non-woven fabric. This is because it is a cause of breakdown when used in a printer or the like. Therefore, since the paper is more suitable than a non-woven fabric, the sheet may be replaced with a paper. However, it is not problematic if the non-woven fabric is used.

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  • Engineering & Computer Science (AREA)
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  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
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EP4015691B1 (de) 2023-04-05
JP6609898B2 (ja) 2019-11-27
WO2015049821A1 (ja) 2015-04-09
CN109338595B (zh) 2021-07-16
EP3054043B1 (de) 2022-03-16
US11001949B2 (en) 2021-05-11
TW201927504A (zh) 2019-07-16
JP2015092032A (ja) 2015-05-14
TWI656955B (zh) 2019-04-21
EP3054043A1 (de) 2016-08-10
TWI672210B (zh) 2019-09-21
BR112016006828A2 (pt) 2017-08-01
TW201825253A (zh) 2018-07-16
CN105531414B (zh) 2018-11-09
EP3054043A4 (de) 2017-04-19
US20210222336A1 (en) 2021-07-22
EP4015691A1 (de) 2022-06-22
US20190316283A1 (en) 2019-10-17
TW201513983A (zh) 2015-04-16
CN105531414A (zh) 2016-04-27
CN109338595A (zh) 2019-02-15
TWI624343B (zh) 2018-05-21

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