US20220098793A1

US20220098793A1 - Fibrous body manufacturing apparatus, fibrous body manufacturing method, ground sheet, and functional sheet

Info

Publication number: US20220098793A1
Application number: US17/485,593
Authority: US
Inventors: Toshiaki Yamagami; Sotaro OANA; Makoto OMURA
Original assignee: Seiko Epson Corp
Current assignee: Seiko Epson Corp
Priority date: 2020-09-28
Filing date: 2021-09-27
Publication date: 2022-03-31
Also published as: JP2022054925A

Abstract

A fibrous body manufacturing apparatus includes a putting-out unit, a transportation unit, a deposition unit, and a pressing and heating unit. The putting-out unit puts a ground sheet out, with a functional member arranged on one side of a sheet. The transportation unit transports the ground sheet put out onto itself. The deposition unit lets fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon. The pressing and heating unit applies pressure and heat to the web.

Description

The present application is based on, and claims priority from JP Application Serial Number 2020-162203, filed Sep. 28, 2020, the disclosure of which is hereby incorporated by reference herein in its entirety.

BACKGROUND

1. Technical Field

Embodiments of the present disclosure relate to a fibrous body manufacturing apparatus, a fibrous body manufacturing method, a ground sheet, and a functional sheet.

2. Related Art

In related art, the use of a special kind of paper called as security paper has been proposed as one methods for enhancing security, for example, as disclosed in JP-A-2020-097802. Security paper is, for example, produced by embedding magnetic wires that exhibit a large Barkhausen effect in a sheet material in a papermaking process. When an alternating magnetic field having a predetermined frequency is applied to this type of paper, the magnetic wire embedded in the paper causes steep magnetization reversal. By detecting the magnetization reversal using a detection device installed in, for example, a gate, it is possible to detect the presence of the paper that includes the magnetic wires.
However, magnetic wires embedded in such security paper, in some instances, could become exposed on the surface of the paper. If magnetic wire exposure occurs, the performance of printing on the paper will deteriorate when the paper is used for a print purpose.

SUMMARY

A fibrous body manufacturing apparatus according to a certain aspect of the present disclosure includes: a putting-out unit that puts a ground sheet out, with a functional member arranged on one side of a sheet; a transportation unit that transports the ground sheet put out onto itself; a deposition unit that lets fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon; and a pressing and heating unit that applies pressure and heat to the web.
A fibrous body manufacturing method according to a certain aspect of the present disclosure includes: putting a ground sheet out, with a functional member arranged on one side of a sheet; transporting the ground sheet put out; letting fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon; and pressing and heating the web.
A ground sheet according to a certain aspect of the present disclosure is to be used by a fibrous body manufacturing apparatus and includes: a sheet; and a functional member arranged on one side of the sheet; wherein the ground sheet has a roll shape.
A functional sheet according to a certain aspect of the present disclosure includes: a sheet; a functional member; an adhesive layer that bonds the functional member to the sheet; and a concealing layer provided on a surface of the adhesive layer and configured to hide the adhesive layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a fibrous body manufacturing apparatus according to a first embodiment.

FIG. 2 is a schematic view of a putting-out unit of the fibrous body manufacturing apparatus according to the first embodiment.

FIG. 3 is a schematic view of the putting-out unit of the fibrous body manufacturing apparatus according to the first embodiment.

FIG. 4 is a schematic plan view of a sheet according to the first embodiment.

FIG. 5 is a schematic cross-sectional view of a sheet according to the first embodiment.

FIG. 6 is a schematic plan view of a sheet according to the first embodiment.

FIG. 7 is a schematic plan view of a sheet according to the first embodiment.

FIG. 8 is a flowchart for explaining a method for manufacturing a fibrous body according to the first embodiment.

FIG. 9 is a schematic view of a fibrous body manufacturing apparatus according to a second embodiment.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

With reference to the accompanying drawings, a certain non-limiting advantageous embodiment of the present disclosure will now be explained in detail. The specific embodiment described below shall never be construed to unduly limit the scope of the present disclosure recited in the appended claims. Not all of components described below necessarily constitute indispensable parts of the present disclosure.

1. First Embodiment

1.1. Fibrous Body Manufacturing Apparatus

1.1.1. Overall Configuration

First, with reference to the accompanying drawings, a fibrous body manufacturing apparatus according to a first embodiment will now be explained. FIG. 1 is a schematic view of a fibrous body manufacturing apparatus 100 according to a first embodiment.
As illustrated in FIG. 1, the fibrous body manufacturing apparatus 100 includes, for example, a supplying unit 10, a coarse crushing unit 12, a defibrating unit 20, a screening unit 40, a first web forming unit 45, a rotator 49, a mixing unit 50, a deposition unit 60, a second web forming unit 70, a sheet forming unit 80, and a cutting unit 90.
The supplying unit 10 supplies a raw material to the coarse crushing unit 12. For example, the supplying unit 10 is an automatic feeder for successive inputs of a raw material into the coarse crushing unit 12. The raw material supplied by the supplying unit 10 contains fibers, for example, fibers of waste paper or pulp sheets.
The coarse crushing unit 12 shreds the raw material supplied by the supplying unit 10 into small pieces under atmospheric conditions, for example, in air. The small pieces are, for example, pieces of a few square centimeters. In the illustrated example, the coarse crushing unit 12 has coarse crushing blades 14, and is able to shred the inputted raw material by means of the coarse crushing blades 14. For example, a shredder is used as the coarse crushing unit 12. After shredding by the coarse crushing unit 12, the raw material is received by a hopper 1, and is sent to the defibrating unit 20 through a pipe 2.
The defibrating unit 20 defibrates the raw material shredded by the coarse crushing unit 12. The term “defibrate” as used herein means the act of disentangling a raw material made up of fibers bound to one another into individual unbound pieces. In addition to the defibrating function, the defibrating unit 20 has a function of separating, from the fibers, resin particles adhering to the raw material, and other substances adhering thereto such as ink, toner, and blurring inhibitor, etc.
The output from the defibrating unit 20 is called as “defibrated material”. The “defibrated material” sometimes contains, in addition to defibrated fibers, resin particles separated from the fibers in the process of defibration, a colorant such an ink, toner, etc., an additive such as blurring inhibitor, paper-strengthening agent, etc. The defibrated material has a string shape or a ribbon shape. The defibrated material may be in a state in which it is not intertwined with any other defibrated fiber, that is, in an independent state. Alternatively, the defibrated material may be in a state of so-called “lump”, in which it is intertwined with other defibrated material.
The defibrating unit 20 performs dry defibration. The term “dry” as used herein means a method in which processing such as defibration is performed under atmospheric conditions, for example, in air, not in a liquid. An impeller mill, for example, is used as the defibrating unit 20. The defibrating unit 20 has a function of producing a flow of air for sucking in the raw material and putting out the defibrated material. By utilizing such a self-produced flow of air, the defibrating unit 20 is able to suck in the raw material through an inlet 22 together with the airflow, perform defibration, and then transport the defibrated material to an outlet 24. The defibrated material outputted from the defibrating unit 20 is sent to the screening unit 40 through a pipe 3. The flow of air produced by the defibrating unit 20 may be used also for transporting the defibrated material from the defibrating unit 20 to the screening unit 40. Alternatively, an airflow producing device such as a blower may be provided, and the airflow of the blower may be used for transporting the defibrated material from the defibrating unit 20 to the screening unit 40.
The defibrated material defibrated by the defibrating unit 20 goes into the screening unit 40 through an inlet 42, and is screened thereat on the basis of fiber lengths. The screening unit 40 has, for example, a drum portion 41 and a housing portion 43. The drum portion 41 is housed in the housing portion 43. For example, a sieve is used as the drum portion 41. The drum portion 41 has a net, and is able to sort the inputted defibrated material into a first screened material and a second screened material. The first screened material is made up of fibers or particles that are smaller than the meshes of the net, that is, those whose size is small enough to pass through the net. The second screened material is made up of fibers that are larger than the meshes of the net, yet-to-be-defibrated pieces, and lumps, that is, those whose size is not small enough to pass through the net. The first screened material is sent to the deposition unit 60 through a pipe 7. The second screened material is put out from an outlet 44 to be returned to the defibrating unit 20 through a pipe 8. Specifically, the drum portion 41 is a cylindrical sieve that is driven to rotate by a motor. Examples of the net of the drum portion 41 are: a wire net, an expanded metal net formed by pulling and expanding a metal plate having slits, and a punched metal net formed by punching holes through a metal plate by using a punching press machine, etc.
The first web forming unit 45 transports, to the pipe 7, the first screened material outputted from the screening unit 40. For example, the first web forming unit 45 includes a mesh belt 46, tensioning rollers 47, and a suction mechanism 48.
The suction mechanism 48 is able to suck, onto the surface of the mesh belt 46, the first screened material dispersed in air after passing through the opening of the screening unit 40. The first screened material accumulates on the mesh belt 46 that is moving, thereby forming into a web V thereon. The basic configuration of the mesh belt 46, the tensioning rollers 47, and the suction mechanism 48 is the same as that of a mesh belt 72, tensioning rollers 74, and a suction mechanism 76 of the second web forming unit 70 described later.
The web V formed by going through the processes performed by the screening unit 40 and the first web forming unit 45 contains a lot of air and is therefore soft and slightly bulky. The web V formed by accumulation on the mesh belt 46 is put into the pipe 7 and is then transported to the deposition unit 60.
The rotator 49 is able to cut the web V. In the illustrated example, the rotator 49 has a base portion 49 a and a protruding portion 49 b. The protruding portion 49 b protrudes from the base portion 49 a. The protruding portion 49 b has, for example, a plate-like shape. In the illustrated example, the protruding portion 49 b is made up of four protrusions. The four protrusions 49 b are provided at equal intervals. The base portion 49 a rotates in a direction R. Due to this rotation, the protruding portion 49 b is able to rotate around the base portion 49 a. By cutting the web V by the rotator 49, for example, it is possible to reduce fluctuations in the amount of the defibrated material supplied to the deposition unit 60 per unit time.
The rotator 49 is provided near the first web forming unit 45. In the illustrated example, the rotator 49 is provided near the tensioning roller 47 a located on the downstream position of the path of the web V. The rotator 49 is provided at a position where the protruding portion 49 b is able to come into contact with the web V but does not come into contact with the mesh belt 46 on which the web V is deposited. Therefore, it is possible to prevent the mesh belt 46 from being abraded by the protruding portion 49 b. The minimum distance between the protruding portion 49 b and the mesh belt 46 is, for example, 0.05 mm or more and 0.5 mm or less. With this distance, it is possible to cut the web V without damaging the mesh belt 46.
The mixing unit 50 mixes the first screened material, which has passed through the net of the screening unit 40, with an additive that contains resin. The mixing unit 50 includes, for example, an additive supply portion 52, which supplies the additive, a pipe 54, through which the first screened material and the additive are transported, and a blower 56. In the illustrated example, the additive is supplied from the additive supply portion 52 into the pipe 54 via a hopper 9. The pipe 54 is connected from the pipe 7.
In the mixing unit 50, the blower 56 produces a flow of air, and the first screened material and the additive are transported while being mixed with each other inside the pipe 54. The mechanism for mixing the first screened material with the additive is not specifically limited. For example, a propeller that rotates at a high speed may be used for stirring them. A pipe having internal blades may rotate to behave as such a mixer.
A screw feeder illustrated in FIG. 1, or a disk feeder that is not illustrated, etc. can be used as the additive supply portion 52. The additive supplied from the additive supply portion 52 contains resin for bonding the fibers to one another. At the point in time of the supply of the resin, the fibers have not been bonded yet. The resin melts during the process of passing through the sheet forming unit 80. The molten resin bonds the fibers together.
The resin supplied from the additive supply portion 52 is thermoplastic resin or thermosetting resin. Examples of this resin are: AS (Acrylonitrile Styrene) resin, ABS (Acrylonitrile Butadiene Styrene) resin, polypropylene, polyethylene, polyvinyl chloride, polystyrene, acrylic resin, polyester, polyethylene terephthalate, polyphenylene ether, polybutylene terephthalate, nylon, polyamide, polycarbonate, polyacetal, polyphenylene sulfide, polyetherether ketone, and the like. Any of these kinds of resin may be used alone, or a mixture of any of them may be used. The additive supplied from the additive supply portion 52 may be fibrous or powdery.
The additive supplied from the additive supply portion 52 may contain, in addition to the binder resin for bonding the fibers together, a colorant for coloring the fibers, an agglomeration inhibitor for inhibiting the agglomeration of the fibers, an aggregation inhibitor for inhibiting the aggregation of resin molecules, a flame retardant that makes the fibers, etc. incombustible, depending on the type of sheets to be manufactured. The mixture outputted from the mixing unit 50 is sent to the deposition unit 60 through the pipe 54.
The mixture outputted from the mixing unit 50 goes into the deposition unit 60 through an inlet 62. The deposition unit 60 disentangles the intertwined defibrated material, and lets them fall while dispersing them in air. If the resin of the additive supplied from the additive supply portion 52 is fibrous, the deposition unit 60 disentangles the intertwined resin. By this means, the deposition unit 60 is able to form a uniform deposition of the mixture on the second web forming unit 70.
The deposition unit 60 has, for example, a drum portion 61 and a housing portion 63. The drum portion 61 is housed in the housing portion 63. A rotatable cylindrical sieve is used as the drum portion 61. The drum portion 61 has a net, and lets fibers or particles that are smaller than the meshes of the net fall among those included in the mixture outputted from the mixing unit 50. The structure of the drum portion 61 is, for example, the same as the structure of the drum portion 41.
The “sieve” of the drum portion 61 does not necessarily have to have any particular target screening function. That is, the “sieve” used as the drum portion 61 just means a mechanism equipped with a net, and the drum portion 61 may let all of those included in the mixture inputted into the drum portion 61 fall.
The second web forming unit 70 forms a web W by deposition of the output from the deposition unit 60 on itself. The second web forming unit 70 includes, for example, the aforementioned mesh belt 72, tensioning rollers 74, and suction mechanism 76.
The material having passed through the opening of the deposition unit 60 accumulates on the mesh belt 72. The mesh belt 72 is stretched around the tensioning rollers 74. The mesh belt 72 is permeable to air, but is not permeable to the material having passed through the opening of the deposition unit 60. The mesh belt 72 moves due to the rotation of the tensioning rollers 74. The material having passed through the opening of the deposition unit 60 falls and accumulates one after another while the mesh belt 72 moves continuously. As a result, the web W is formed on the mesh belt 72.
The suction mechanism 76 is provided under the mesh belt 72. The suction mechanism 76 is able to produce a downward flow of air. Because of the airflow produced by the suction mechanism 76, it is possible to suck the mixture dispersed in air by the deposition unit 60 onto the mesh belt 72. By this means, it is possible to increase the speed of discharge from the deposition unit 60. Moreover, it is possible to form a downward flow, by the suction mechanism 76, in the path of fall of the mixture; therefore, it is possible to prevent the defibrated material and the additive from becoming entangled while they fall.
Since the web W is formed by going through the processes performed by the deposition unit 60 and the second web forming unit 70 as described above, the web W contains a lot of air and is therefore soft and slightly bulky. The web W formed by deposition on the mesh belt 72 is transported to the sheet forming unit 80.
In the illustrated example, a moisture adjusting unit 78 for adjusting the moisture of the web W is provided. The moisture adjusting unit 78 is able to adjust ambient humidity and the ratio of the web W to water by adding the water, water vapor, or mist to the web W.
The sheet forming unit 80 forms a sheet S by pressing and heating the web W, which has been formed by deposition on the mesh belt 72. At the sheet forming unit 80, heat is applied to the mixture of the defibrated material and the additive in the web W. By this means, it is possible to bond the fibers contained in the mixture to one another by means of the additive.
The sheet forming unit 80 includes a pressing portion 82, which presses the web W, and a heating portion 84, which heats the web W pressed by the pressing portion 82. The pressing portion 82 is made up of a pair of rollers 85. The pressing portion 82 applies pressure to the web W. The pressing decreases the thickness of the web W and increases the bulk density of the web W. Heating rollers, a heat press shaping machine, hot plates, a hot air blower, an infrared heater, or a flash fixation device, for example, can be used as the heating portion 84. In the illustrated example, the heating portion 84 has a pair of heating rollers 86. Since the heating portion 84 is configured as the heating rollers 86, as compared with a case where the heating portion 84 is configured as a plate-type pressing device, it is possible to shape the sheet S while transporting the web continuously. The rollers 85 and the heating rollers 86 are arranged such that, for example, their rotation shafts are in parallel with one another. The rollers 85 are able to apply, to the web W, pressure that is higher than pressure applied by the heating rollers 86 to the web W. The number of the rollers 85 is not specifically limited. The number of the heating rollers 86 is also not specifically limited.
The cutting unit 90 cuts the sheet S produced by the sheet forming unit 80. In the illustrated example, the cutting unit 90 includes a first cutting portion 92, which cuts the sheet S in the direction orthogonal to the direction of transportation of the sheet S, and a second cutting portion 94, which cuts the sheet S in the direction parallel to the transportation direction. For example, the second cutting portion 94 cuts the sheet S having passed through the first cutting portion 92.
The sheet S that has predetermined single-cut size is produced through the above process. The single-cut sheet S is ejected to an ejected sheet receiver 96.

1.1.2. Putting-Out Unit

The fibrous body manufacturing apparatus 100 includes a putting-out unit 110. Each of FIGS. 2 and 3 is a schematic view of the putting-out unit 110 of the fibrous body manufacturing apparatus 100. To facilitate an explanation, in FIG. 1, the illustration of the putting-out unit 110 is simplified. A state after a predetermined time has elapsed from a state illustrated in FIG. 2 is illustrated in FIG. 3.
As illustrated in FIGS. 1, 2, and 3, for example, the putting-out unit 110 includes a first supplying roll 120, a first placing portion 130, and a second placing portion 140. The putting-out unit 110 puts a ground sheet 150 out onto the mesh belt 72. The mesh belt 72 is an example of a transportation unit that transports the ground sheet 150 put out onto itself.
The first supplying roll 120 is a roll of a base sheet 152. The first supplying roll 120 rotates in a direction Q1 when driven by a driving mechanism that is not illustrated. Due to this rotation, the base sheet 152 constituting the first supplying roll 120 is unreeled therefrom and moves toward the mesh belt 72. In the example illustrated in FIGS. 2 and 3, the unreeled part of the first supplying roll 120 is placed on a table 122. In FIG. 1, the table 122 is not illustrated. The base sheet 152 has one side 152 a and the other side 152 b, which is the opposite surface in relation to the one side 152. The other side 152 b is in contact with the mesh belt 72. The material of the base sheet 152 will be described later.
The first placing portion 130 places a functional member 154 on the one side 152 a of the base sheet 152. The first placing portion 130 includes, for example, a second supplying roll 132, rollers 134, a guide 136, and a cutter 138.
The second supplying roll 132 is a roll of the functional member 154, which has a sheet shape when not rolled. The second supplying roll 132 rotates in a direction Q2 when driven by a driving mechanism that is not illustrated. In the illustrated example, the direction Q2 is the opposite of the direction Q1. As illustrated in FIG. 2, the functional member 154 constituting the second supplying roll 132 travels through the rollers 134 and the guide 136 and is placed on the one side 152 a of the base sheet 152. Then, as illustrated in FIG. 3, the functional member 154 is cut by the cutter 138 at a predetermined position. The material of the functional member 154 will be described later.
The second placing portion 140 places an adhesive tape 156 on the one side 152 a of the base sheet 152. By doing so, the second placing portion 140 temporarily fixes a part of the functional member 154 onto the base sheet 152. The second placing portion 140 includes, for example, a third supplying roll 142, a cutter 144, and a base collecting roll 146.
The third supplying roll 142 is a roll of the adhesive tape 156, which has a sheet shape when not rolled. The adhesive tape 156 has a layered structure that includes a base 156 a and a sticky portion 156 b. The third supplying roll 142 rotates in a direction Q3, with the sticky portion 156 b of the adhesive tape 156 pressed against the one side 152 a of the base sheet 152. Due to this rotation, the adhesive tape 156 is unreeled by a predetermined length, the base 156 a and the sticky portion 156 b are separated from each other by the cutter 144, and the base 156 a is reeled onto the base collecting roll 146. In the illustrated example, the direction Q3 is the opposite of the direction Q1. The sticky portion 156 b of the adhesive tape 156, which constitutes the third supplying roll 142, is placed while temporarily fixing the functional member 154 to the one side 152 a of the base sheet 152. Then, the adhesive tape 156 is cut by the cutter 144 at a predetermined position. The material of the adhesive tape 156 will be described later.
The putting-out unit 110 having the configuration described above puts the ground sheet 150 out onto the mesh belt 72, with the functional member 154 placed on the one side 152 a of the base sheet 152. As illustrated in FIG. 1, the mesh belt 72 transports the ground sheet 150 put out onto itself, and the deposition unit 60 lets the mixture that includes the fibers and the binder fall and accumulate on one side 150 a of the ground sheet 150 transported by the mesh belt 72, thereby forming the web W thereon. The suction mechanism 76, which is an example of a sucking unit, is provided below the other side 150 b of the ground sheet 150. The sheet forming unit 80 is an example of a pressing and heating unit that applies pressure and heat to the web W. The one side 150 a of the ground sheet 150 is oriented in the same direction as the one side 152 a of the base sheet 152.

1.2. Sheet

Next, with reference to the accompanying drawings, the sheet S manufactured by the fibrous body manufacturing apparatus 100 described above will now be explained. FIG. 4 is a schematic plan view of the sheet S according to the first embodiment. FIG. 5 is a schematic cross-sectional view of the sheet S according to the first embodiment, taken along the line V-V of FIG. 4.
The sheet S is a rectangular fibrous body cut by the cutting unit 90 into the size of, for example, A4. The sheet S is used as printing paper, and printing is performed thereon by a printer, similarly to plain paper, etc. The sheet S has a thickness of, for example, 50 μm or more and 200 μm or less. Preferably, the sheet S may have a thickness of 90 μm or more and 150 μm or less.
As illustrated in FIGS. 4 and 5, the sheet S includes the ground sheet 150 and a surface layer sheet 160. The ground sheet 150 includes the base sheet 152, the functional member 154, and the sticky portion 156 b. The sheet S is a functional sheet that includes the functional member 154. To facilitate an explanation, in FIG. 4, the surface layer sheet 160 is illustrated in a see-through state.
The base sheet 152 is made of, for example, nonwoven fabric. Preferably, the nonwoven fabric of the base sheet 152 may be made up of fibers that have the same molecular structure as that of fibers discharged from the deposition unit 60. Examples of the fibers contained in the base sheet 152 are: cellulose fibers, rayon, cotton, linters, kapok, flax, hemp, and ramie. Any one of those enumerated here may be used alone, or two or more of them may be used in combination. A preferred example of the fibers contained in the base sheet 152 is cellulose fibers. Cellulose fibers are easily available and have excellent formability. Preferably, the cellulose fibers may be fibers derived from wood-based pulp. Examples of the wood-based pulp are: virgin pulp, Kraft pulp, bleached chemi-thermo mechanical pulp, synthetic pulp, or pulp derived from waste paper or recycled paper. Any one of those enumerated here may be used alone, or two or more of them may be used in combination.
The base sheet 152 is permeable to air. The term “air permeability” as used herein means the property of allowing air to pass through a plurality of pores. Preferably, the Gurley second, which indicates the degree of air permeability, of the base sheet 152 may be 30 seconds or less when measured using a Gurley permeability tester. More preferably, the Gurley second of the base sheet 152 may be 15 seconds or less.
The functional member 154 is disposed on the one side 152 a of the base sheet 152. Specifically, the functional member 154 is bonded to the one side 152 a of the base sheet 152 by an adhesive layer 157. The functional member 154 is, for example, a magnetic body made of a magnetic material. Specifically, the functional member 154 is a magnetic wire made of a magnetic material and having a length in the order of several millimeters or more. The sheet S includes, for example, a plurality of functional members 154. In the example illustrated in FIG. 4, the sheet S includes six functional members 154. These functional members 154 are arranged radially in a plan view. These functional members 154 do not overlap with one another in a plan view. In the example illustrated in FIG. 4, among the six functional members 154, functional members 154 a and 154 b have their longitudinal direction in a first direction, functional members 154 c and 154 d have their longitudinal direction in a second direction, which is inclined by 60° with respect to the first direction, and functional members 154 e and 154 f have their longitudinal direction in a third direction, which is inclined by 60° with respect to the first and second directions. The functional member 154 a does not overlap with another functional member 154 b in a plan view. For example, by moving the first placing portion 130 and the second placing portion 140 with respect to the base sheet 152 by a moving mechanism that is not illustrated, it is possible to arrange the functional members 154 at predetermined positions.
Since the sheet S includes the functional member 154 that is a magnetic wire, the sheet S can be used as security paper. The security paper is a medium realized in the form of paper detectable by a detection system equipped with an exciting coil and a detecting coil. An alternating current is applied to the exciting coil to generate an alternating magnetic field, and the sheet S is placed in the alternating magnetic field. It is possible to detect the presence of the sheet S when magnetization reversal occurs. Therefore, by disposing the exciting coil and the detecting coil in a gate where persons or vehicles are able to pass, it is possible to detect the sheet S carried through the gate. Accordingly, it is possible to detect an unauthorized act of carrying the sheet S out. For example, if confidential information, etc. is printed on the sheet S, it is possible to prevent the leakage of the confidential information.
It is preferable if the functional member 154 exhibits a large Barkhausen effect. Specifically, the material of the functional member 154 is FeCr-based, FeCo-based, FeNi, FeSiB, or FeCoSiB-based alloy. These materials can be used suitably because they exhibit a large Barkhausen effect even without applying strain by post processing. Strain may be applied by post processing so as to impart large Barkhausen properties. The functional member 154 may be a wire formed by cutting an amorphous ribbon. The functional member 154 may be a glass-coated wire formed by drawing such amorphous metal together with glass from a molten state and by cooling them.
Preferably, the functional member 154 may have a longitudinally-long line-like shape such as a wire shape or a ribbon shape. Having a predetermined length relative to a cross-sectional area size makes it easier to exhibit a large Barkhausen effect.
Preferably, the diameter of the functional member 154 may be 10 μm or more and 100 μm or less when the functional member 154 has a wire shape. If the functional member 154 has a diameter of 10 μm or more, it is easier to exhibit a large Barkhausen effect. If the functional member 154 has a diameter of 100 μm or less, the functional member 154 does not become exposed from the sheet S. Moreover, if the functional member 154 has a diameter of 100 μm or less, it is possible to cut the functional member 154 with the cutter 138 easily.
Preferably, the thickness of the functional member 154 may be 10 μm or more and 100 μm or less when the functional member 154 has a ribbon shape. If the functional member 154 has a thickness of 10 μm or more, it is easier to exhibit a large Barkhausen effect. If the functional member 154 has a thickness of 100 μm or less, the functional member 154 does not become exposed from the sheet S. Moreover, if the functional member 154 has a thickness of 100 μm or less, it is possible to cut the functional member 154 with the cutter 138 easily. Preferably, the width of the functional member 154 may be, for example, 50 μm or more and 1,000 μm or less when the functional member 154 has a ribbon shape.
Preferably, the length of the functional member 154 may be 10 mm or more, or more preferably, 50 mm or more, when the functional member 154 has a wire shape or a ribbon shape. If the length of the functional member 154 is 10 mm or more, in synergy with the effect of shape anisotropy, it is easier to exhibit an NS reversal effect. Moreover, if the length of the functional member 154 is 10 mm or more, it is easier to place the functional member 154 at a desired position. There is no upper limit in the length of the functional member 154 except that it is not greater than the size of the cut sheet S. For example, the length of the functional member 154 is 200 mm or less.
With regard to the diameter and the length of the functional member 154, it is preferable if the diameter and the length of all of the functional members 154 included in the sheet S are within the ranges described above. However, if there is a distribution in the values of them, it is preferable if the average of the values of the diameter of them and the average of the values of the length of them are within the ranges described above. If the functional member 154 is bent, the minimum distance from one end of the functional member 154 to the other end thereof is defined as the length of the functional member 154.
It is possible to numerically define the functional members 154 in terms of, for example, weight in the sheet S cut by the cutting unit 90. For example, if the weight of the sheet S is expressed as 100 parts by weight, preferably, the weight of the functional member 154 may be 1.0 part by weight or less. In other words, the fibrous body manufacturing apparatus 100 manufactures the sheet S by performing cutting by the cutting unit 90 at a position where the weight of the functional member 154 is 1.0 part by weight or less when the weight of the sheet S is 100 parts by weight.
The sticky portion 156 b is provided on the functional member 154. In the illustrated example, the sticky portion 156 b made up of two sticky parts is provided on each one functional member 154. The sticky portion 156 b is provided on one end and the other end of the functional member 154. The number of the sticky parts constituting the sticky portion 156 b on each functional member 154 is not specifically limited. However, by providing the sticky portion 156 b on one end and the other end of the functional member 154, it is possible to flexibly accommodate the stretching of the base sheet 152. The sticky portion 156 b is the portion that remains after the removal of the base 156 a from the adhesive tape 156. The sticky portion 156 b is, for example, a so-called correction tape. The sticky portion 156 b includes the adhesive layer 157 and a concealing layer 158.
The adhesive layer 157 bonds the functional member 154 to the base sheet 152. The adhesive layer 157 bonds the concealing layer 158 and the functional member 154 to the one side 152 a of the base sheet 152. The material of the adhesive layer 157 is, for example, a natural rubber adhesive. Specifically, a tackifier and an oxidation inhibitor are added to natural rubber.
The concealing layer 158 is provided on the surface 157 a of the adhesive layer 157. The concealing layer 158 hides the adhesive layer 157. That is, the concealing layer 158 makes it difficult for the adhesive layer 157 to be seen when viewed from the side where the one side 150 a of the ground sheet 150 is present. The material of the concealing layer 158 is, for example, a mixture of methyl cyclohexane serving as a solvent, acrylic resin serving as a fixing agent, and titanium oxide serving as a pigment. The color of the concealing layer 158 is white because it contains titanium oxide, which is a white pigment. Therefore, when the color of the base sheet 152 and the color of the surface layer sheet 160 are white, this makes the concealing layer 158 hard to spot. The concealing layer 158 does not have adhesiveness.
The pigment contained in the concealing layer 158 can be selected to suit the color of the base sheet 152 and the color of the surface layer sheet 160. The solvent and the fixing agent contained in the concealing layer 158 can be selected to suit the pigment contained in the concealing layer 158.
Preferably, the concealing layer 158 and the adhesive layer 157 may be permeable to air. Each of the concealing layer 158 and the adhesive layer 157 is able to allow air to pass through a plurality of pores. The permeability of the concealing layer 158 and the adhesive layer 157 makes it easier to suck the fibers and the binder from the deposition unit 60 by the suction mechanism 76.
When the adhesive tape 156 is prepared in a roll shape as illustrated in FIG. 2, preferably, the adhesive tape 156 and a non-illustrated base tape may be formed into a roll in a stacked state. When the functional member 154 is to be temporarily fixed with the adhesive tape 156, the non-illustrated base tape should preferably be taken off the adhesive tape 156. This makes it possible to feed the adhesive tape 156 prepared in a roll shape onto the base sheet 152 easily.
The surface layer sheet 160 is provided on the one side 150 a of the ground sheet 150. The base sheet 152, the functional member 154, and the adhesive tape 156 are covered by the surface layer sheet 160. The surface layer sheet 160 contains the fibers of the raw material supplied by the supplying unit 10 and the binder that is the resin supplied from the additive supply portion 52. The fibers and the binder contained in the surface layer sheet 160 are those discharged from the deposition unit 60. By being heated by the heating portion 84, the binder bonds the fibers discharged from the deposition unit 60 together and bonds, to the base sheet 152, the fibers discharged from the deposition unit 60. In addition, the binder bonds the functional member 154 and the base sheet 152 to each other. Furthermore, the binder bonds, to the functional member 154, the fibers discharged from the deposition unit 60.
In the example illustrated in FIG. 4, the functional members 154 are arranged radially. However, the arrangement of the functional members 154 is not limited to such a radial layout. The arrangement of the functional members 154 may be modified as long as they do not overlap with one another. For example, in a state in which the functional members 154 a and 154 b have their longitudinal direction in the first direction, the functional members 154 c and 154 d have their longitudinal direction in the second direction, and the functional members 154 e and 154 f have their longitudinal direction in the third direction, the functional members 154 may be arranged in such a way as to surround the center of the base sheet 152 as illustrated in FIG. 6. Alternatively, the functional members 154 may be arranged randomly as illustrated in FIG. 7. By arranging the functional members 154 in such a way as to have different longitudinal directions, it is possible to make the functional members 154 easier to be detected, for example, as compared with a case where the functional members 154 have the same longitudinal direction.
The functional member 154 has been described as a magnetic body above. However, the functional member 154 does not have to be a magnetic body as long as the functional member 154 in the sheet S is detectable by external contact-less detection. For example, the functional member 154 may be a metallic wire configured to be detected by a metal detector. The functional member 154 may be an RF (Radio Frequency) tag configured to be detected by an RFID (Radio Frequency Identification) reader. The functional member 154 may be an IC (Integrated Circuit) chip.
The sheet S may have a structure formed by providing a non-illustrated nonwoven fabric sheet on the surface of the surface layer sheet 160. To put it another way, the surface layer sheet 160 may be located between the base sheet 152 and the nonwoven fabric sheet. However, omitting such a sheet made of nonwoven fabric will be advantageous for reducing cost.

1.3. Method for Manufacturing Sheet

Next, with reference to the accompanying drawings, a method for manufacturing the sheet S according to the first embodiment will now be explained. FIG. 8 is a flowchart for explaining a method for manufacturing the sheet S according to the first embodiment. The sheet S is manufactured using, for example, the fibrous body manufacturing apparatus 100 described above.
As illustrated in FIG. 8, the method for manufacturing the sheet S includes a putting-out process (step S1), a transportation process (step S2), a deposition process (step S3), and a pressing and heating process (step S4). The putting-out process (step S1) is a process of putting the ground sheet 150 out, with the functional member 154 placed on the one side 152 a of the base sheet 152. The transportation process (step S2) is a process of transporting the ground sheet 150 having been put out. The deposition process (step S3) is a process of letting the fibers and the binder deposit on the one side 150 a of the transported ground sheet 150, thereby forming the web W thereon. The pressing and heating process (step S4) is a process of applying pressure and heat to the web W.
The putting-out process (step S1) is executed by the putting-out unit 110 of the fibrous body manufacturing apparatus 100. The transportation process (step S2) is executed by the mesh belt 72. The deposition process (step S3) is executed by the deposition unit 60. The pressing and heating process (step S4) is executed by the sheet forming unit 80, which includes the pressing portion 82 and the heating portion 84.
In addition to the processes described above, the method for manufacturing the sheet S may include other processes executed by the components of the fibrous body manufacturing apparatus 100 described above.

1.4. Operational Effects

The fibrous body manufacturing apparatus 100 includes the putting-out unit 110, which puts the ground sheet 150 out, with the functional member 154 placed on the one side 152 a of the base sheet 152, the mesh belt 72, which transports the ground sheet 150 put out onto itself, the deposition unit 60, which lets the fibers and the binder deposit on the one side 150 a of the transported ground sheet 150, thereby forming the web W thereon, and the sheet forming unit 80, which applies pressure and heat to the web W. As described above, the fibrous body manufacturing apparatus 100 manufactures the sheet S, with the functional members 154 sandwiched between the base sheet 152 and the pressed and heated web W (the surface layer sheet 160). For this reason, the fibrous body manufacturing apparatus 100 is able to manufacture the sheet S that has a low risk of exposure of the functional member 154 on its surface even if, for example, the sheet S is bent or folded. Therefore, the sheet S manufactured by the fibrous body manufacturing apparatus 100 has high printability.
Moreover, the sheet S manufactured by the fibrous body manufacturing apparatus 100 offers higher print performance because printing is performed on its surface layer sheet 160 containing fibers, as compared with a case where, for example, printing is performed on a coat layer (a coat layer not containing fibers) provided on a sheet surface for the purpose of preventing a functional member from becoming exposed.
The fibrous body manufacturing apparatus 100 includes the suction mechanism 76, which is provided below the other side 150 b of the ground sheet 150. The base sheet 152 is permeable to air. Therefore, in the fibrous body manufacturing apparatus 100, it is easier to suck the fibers and the binder from the deposition unit 60 by the suction mechanism 76, as compared with a case where the base sheet 152 is not permeable to air.
In the fibrous body manufacturing apparatus 100, the functional member 154 is bonded to the base sheet 152 by the adhesive layer 157, and the concealing layer 158 for hiding the adhesive layer 157 is provided on the surface 157 a of the adhesive layer 157. Therefore, in the fibrous body manufacturing apparatus 100, as compared with a case where no concealing layer is provided, such a concealing structure makes it difficult for the adhesive layer 157 to be seen when viewed from the side where the one side 150 a of the ground sheet 150 is present. Moreover, it is possible to reduce the risk of movement of the functional member 154 in relation to the base sheet 152 during the movement of the ground sheet 150.
For example, if a liquid adhesive is used for the bonding of the functional member, the adhesive will seep into the base sheet and spreads, resulting in a stain. Such a stain is obstructive to printing. If a wax is used for the bonding of the functional member, the wax will melt when heated by the heating portion, resulting in a stain, as is the case with a liquid adhesive. In the fibrous body manufacturing apparatus 100, it is possible to avoid the above problems because the adhesive layer 157 is used for the bonding.
The fibrous body manufacturing apparatus 100 includes the defibrating unit 20, which defibrates a raw material to form a defibrated material containing fibers, and the mixing unit 50, which forms a mixture by mixing the defibrated material with a binder. The deposition unit 60 lets the mixture deposit. Therefore, the fibrous body manufacturing apparatus 100 is able to let the mixture containing the defibrated material and the binder deposit on the mesh belt 72.
In the fibrous body manufacturing apparatus 100, another functional member 154 b is arranged on the one side 152 a of the base sheet 152, and the functional member 154 a and this another functional member 154 b do not overlap with each other. Therefore, the fibrous body manufacturing apparatus 100 is able to manufacture the sheet S that has a higher degree of flatness as compared with a case where a functional member and another functional member overlap with each other.
In the fibrous body manufacturing apparatus 100, the putting-out unit 110 includes the first placing portion 130, which arranges the functional members 154 on the base sheet 152. Therefore, the fibrous body manufacturing apparatus 100 is able to manufacture the ground sheet 150.

2. Second Embodiment

Next, with reference to the accompanying drawings, a fibrous body manufacturing apparatus according to a second embodiment will now be explained. FIG. 9 is a schematic view of a fibrous body manufacturing apparatus 200 according to a second embodiment.
In the description of the fibrous body manufacturing apparatus 200 according to the second embodiment below, the same reference numerals are assigned to components having the same functions as those of the fibrous body manufacturing apparatus 100 according to the first embodiment described above, and a detailed explanation of them is omitted.
In the fibrous body manufacturing apparatus 100 described above, as illustrated in FIG. 1, the putting-out unit 110 includes the first placing portion 130 and the second placing portion 140. By contrast, in the fibrous body manufacturing apparatus 200, as illustrated in FIG. 9, the putting-out unit 110 does not include the first placing portion 130 and the second placing portion 140.
In the fibrous body manufacturing apparatus 200, the putting-out unit 110 includes a cabinet portion 210 inside which the ground sheet 150 is housed. The ground sheet 150, when housed, is in the shape of a roll. Namely, the first supplying roll 120 housed inside the cabinet portion 210 is a roll of the ground sheet 150. The cabinet portion 210, together with the ground sheet 150, is replaceable. Therefore, the user is able to select a desired ground sheet 150 and install the cabinet portion 210 onto the fibrous body manufacturing apparatus 200. In the fibrous body manufacturing apparatus 200, the putting-out unit 110 includes the cabinet portion 210 inside which the ground sheet 150 is housed, and the ground sheet 150, when housed, is in the shape of a roll. Therefore, it is unnecessary to provide the placing portions 130 and 140, resulting in a compact apparatus configuration.
The foregoing exemplary embodiments and the modification examples are just examples. The scope of the present disclosure is not limited to these examples. For example, the foregoing exemplary embodiment(s) and the modification example(s) may be combined as needed.
The present disclosure encompasses every structure that is substantially the same as the structure described in the foregoing exemplary embodiments, for example, structure with the same function, method, and result, or structure with the same object and effect. The present disclosure encompasses every structure that is obtained by replacement of a non-essential part(s) in the structure described in the foregoing exemplary embodiments. The present disclosure encompasses every structure that produces the same operational effect as that of the structure described in the foregoing exemplary embodiments, or structure that achieves the same object as that of the structure described in the foregoing exemplary embodiments. The present disclosure encompasses every structure that is obtained by addition of known art to the structure described in the foregoing exemplary embodiments.
The following content of disclosure can be derived from the foregoing exemplary embodiments and modification examples.
A fibrous body manufacturing apparatus according to a certain aspect of the disclosed embodiments includes: a putting-out unit that puts a ground sheet out, with a functional member arranged on one side of a sheet; a transportation unit that transports the ground sheet put out onto itself; a deposition unit that lets fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon; and a pressing and heating unit that applies pressure and heat to the web.
The fibrous body manufacturing apparatus according to the above aspect manufactures a sheet, with functional members sandwiched between a base sheet and a pressed and heated web. For this reason, it is possible to manufacture the sheet that has a low risk of exposure of the functional member on its surface even if, for example, the sheet is bent or folded.
The fibrous body manufacturing apparatus according to the above aspect may further include a sucking unit provided on a side where the other side of the ground sheet is present; wherein the sheet may be permeable to air.
Having this structure, the fibrous body manufacturing apparatus according to the above aspect makes it easier to suck the fibers and the binder from the deposition unit by the sucking unit.
In the fibrous body manufacturing apparatus according to the above aspect, the functional member may be bonded to the sheet by an adhesive layer, and a concealing layer for hiding the adhesive layer may be provided on a surface of the adhesive layer.
This structure of the fibrous body manufacturing apparatus according to the above aspect makes it difficult for the adhesive layer to be seen when viewed from the side where the one side of the ground sheet is present.
The fibrous body manufacturing apparatus according to the above aspect may further include: a defibrating unit that defibrates a raw material to form a defibrated material containing fibers; and a mixing unit that forms a mixture by mixing the defibrated material with the binder; wherein the deposition unit may let the mixture deposit.
Having this structure, the fibrous body manufacturing apparatus according to the above aspect is able to let the mixture containing the defibrated material and the binder deposit on the transportation unit.
In the fibrous body manufacturing apparatus according to the above aspect, another functional member may be arranged on the one side of the sheet, and the functional member and the another functional member may be configured not to overlap with each other.
Having this structure, the fibrous body manufacturing apparatus according to the above aspect is able to manufacture a sheet that has a higher degree of flatness.
In the fibrous body manufacturing apparatus according to the above aspect, the putting-out unit may include an arranging unit that arranges the functional member on the sheet.
Having this structure, the fibrous body manufacturing apparatus according to the above aspect is able to manufacture a ground sheet.
In the fibrous body manufacturing apparatus according to the above aspect, the putting-out unit may include a housing unit inside which the ground sheet is housed, and the ground sheet, when housed, may be in a shape of a roll.
Having this structure, the fibrous body manufacturing apparatus according to the above aspect makes it unnecessary to provide an arranging unit. Therefore, the fibrous body manufacturing apparatus having this structure is compact.
A fibrous body manufacturing method according to a certain aspect of the disclosed embodiments includes: putting a ground sheet out, with a functional member arranged on one side of a sheet; transporting the ground sheet put out; letting fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon; and pressing and heating the web.
A ground sheet according to a certain aspect of the disclosed embodiments is to be used by a fibrous body manufacturing apparatus and includes: a sheet; and a functional member arranged on one side of the sheet; wherein the ground sheet has a roll shape.
A functional sheet according to a certain aspect of the disclosed embodiments includes: a sheet; a functional member; an adhesive layer that bonds the functional member to the sheet; and a concealing layer provided on a surface of the adhesive layer and configured to hide the adhesive layer.

Claims

What is claimed is:

1. A fibrous body manufacturing apparatus, comprising:

a putting-out unit that puts a ground sheet out, with a functional member arranged on one side of a sheet;

a transportation unit that transports the ground sheet put out onto itself;

a deposition unit that lets fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon; and

a pressing and heating unit that applies pressure and heat to the web.

2. The fibrous body manufacturing apparatus according to claim 1, further comprising:

a sucking unit provided on a side where an other side of the ground sheet is present; wherein

the sheet is permeable to air.

3. The fibrous body manufacturing apparatus according to claim 1, wherein

the functional member is bonded to the sheet by an adhesive layer, and

a concealing layer for hiding the adhesive layer is provided on a surface of the adhesive layer.

4. The fibrous body manufacturing apparatus according to claim 1, further comprising:

a defibrating unit that defibrates a raw material to form a defibrated material containing fibers; and

a mixing unit that forms a mixture by mixing the defibrated material with the binder; wherein

the deposition unit lets the mixture deposit.

5. The fibrous body manufacturing apparatus according to claim 1, wherein

another functional member is arranged on the one side of the sheet, and

the functional member and the another functional member do not overlap with each other.

6. The fibrous body manufacturing apparatus according to claim 1, wherein

the putting-out unit includes an arranging unit that arranges the functional member on the sheet.

7. The fibrous body manufacturing apparatus according to claim 1, wherein

the putting-out unit includes a housing unit inside which the ground sheet is housed, and

the ground sheet, when housed, is in a shape of a roll.

8. A fibrous body manufacturing method, comprising:

putting a ground sheet out, with a functional member arranged on one side of a sheet;

transporting the ground sheet put out;

letting fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon; and

pressing and heating the web.

9. A ground sheet to be used by a fibrous body manufacturing apparatus, the ground sheet comprising:

a sheet; and

a functional member arranged on one side of the sheet; wherein

the ground sheet has a roll shape.

10. A functional sheet, comprising:

a sheet;

a functional member;

an adhesive layer that bonds the functional member to the sheet; and

a concealing layer provided on a surface of the adhesive layer and configured to hide the adhesive layer.