WO2016035255A1 - 繊維シート及びその製造方法 - Google Patents
繊維シート及びその製造方法 Download PDFInfo
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- WO2016035255A1 WO2016035255A1 PCT/JP2015/003934 JP2015003934W WO2016035255A1 WO 2016035255 A1 WO2016035255 A1 WO 2016035255A1 JP 2015003934 W JP2015003934 W JP 2015003934W WO 2016035255 A1 WO2016035255 A1 WO 2016035255A1
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- fiber
- sheet
- particles
- fibers
- particle
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
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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
- D04H1/02—Cotton wool; Wadding
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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
- D04H1/40—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
- D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
Definitions
- a fiber sheet and a manufacturing method thereof are disclosed. More specifically, a fiber sheet including fiber particles and a method for manufacturing the same are disclosed.
- Patent Document 1 Japanese Patent Publication No. 3-45134 discloses a mattress in which a fiber ball is filled in a cover.
- An object of the present disclosure is to provide a new material using fiber particles.
- the fiber sheet of the present disclosure includes a plurality of fiber particles formed by entanglement of fibers.
- the plurality of fiber particles are three-dimensionally entangled with fibers that have jumped out to the periphery.
- the plurality of fiber particles are bonded by heat-welding fibers contained in the plurality of fiber particles.
- the method for producing a fiber sheet according to the present disclosure includes entangled fibers to form a plurality of fiber particles; and three-dimensionally arranging the plurality of fiber particles into a sheet shape; Heating the plurality of fiber grains and bonding the plurality of fiber grains with heat-weldable fibers contained in the plurality of fiber grains.
- the fiber sheet of the present disclosure includes fiber particles, it has excellent elasticity and high cushioning properties. Since the fiber sheet of this indication can hold air, it is excellent in heat insulation. Since the fiber sheet of the present disclosure is a sheet provided with fiber particles, it can be applied not only to bedding and clothing, but also as a vehicle mat and a base material in the medical and agricultural fields.
- the fiber sheet manufacturing method of the present disclosure can easily manufacture a fiber sheet provided with fiber particles.
- FIG. 1 consists of FIGS. 1A and 1B.
- FIG. 1A is a perspective view.
- FIG. 1B is an enlarged cross-sectional view. It is a typical front view of an example of a fiber grain.
- FIG. 4 is a schematic configuration diagram illustrating an example of a fiber grain arranging device.
- FIG. 4 consists of FIGS. 4A and 4B.
- 4A is a side view and
- FIG. 4B is a front view.
- FIG. 5 consists of FIGS. 5A and 5B.
- FIG. 5A is a photograph of an example of fiber particles.
- FIG. 5B is a photograph of an example of a fiber sheet.
- FIG. 7 is a photograph of an example of different types of fiber particles.
- FIG. 7 consists of FIGS. 7A to 7D.
- 7A shows the fiber particles (2p) of Example 1
- FIG. 7B shows the fiber particles (2q) of Example 2
- FIG. 7C shows the fiber particles (2r) of Example 3
- FIG. These show the fiber grain (2s) of the grain example 4.
- FIG. 1 schematically shows an example of the fiber sheet 1.
- FIG. 1 consists of FIG. 1A and FIG. 1B.
- FIG. 1 it can be seen that a plurality of fiber particles 2 exist in the fiber sheet 1.
- FIG. 2 schematically shows an example of fiber particles 2 used for the fiber sheet 1. 1 and 2 are schematically shown for easy understanding, and the actual one may be different from the embodiment shown in the drawings.
- the fiber sheet 1 includes a plurality of fiber grains 2.
- the fiber particle 2 is formed by entangled with the fiber 3.
- the plurality of fiber particles 2 are three-dimensionally entangled by the fibers 3a that protrude to the periphery.
- the plurality of fiber particles 2 are bonded by heat-weldable fibers contained in the plurality of fiber particles 2. Since the fiber sheet 1 includes the fiber particles 2, the fiber sheet 1 has excellent elasticity and high cushioning properties. Since the fiber sheet 1 can hold air, it is excellent in heat insulation. Since the fiber sheet 1 is a sheet provided with fiber particles 2, it can be applied not only to bedding and clothing, but also as a vehicle mat and a base material in the medical and agricultural fields.
- the fiber particle 2 is composed of a plurality of fibers 3.
- a fiber grain 2 is formed by tangling a plurality of fibers 3. From the fiber grain 2, a part of the fiber 3 protrudes to the periphery.
- the fiber 3 jumping out around is defined as a fiber 3a.
- the ends of the fibers 3 a may be arranged outside the mass of the fiber particles 2.
- the fiber grain 2 is preferably substantially spherical. Thereby, the fiber particles 2 can be more easily arranged three-dimensionally.
- the substantially spherical shape may be a shape that feels round when viewed with the naked eye.
- the fiber grain 2 may have a round shape having no corners.
- the average particle size of the fiber particles 2 is preferably in the range of 1 to 50 mm. Thereby, elasticity can be improved.
- the average particle diameter of the fiber particles 2 is more preferably in the range of 2 to 30 mm, further preferably in the range of 2 to 20 mm, and still more preferably in the range of 3 to 10 mm.
- the average particle diameter is measured with reference to the rounded portion of the fiber excluding the protruding fiber 3a.
- the average particle diameter is obtained by measuring and averaging the dimensions of a predetermined number (for example, 100) of the fiber grains 2. The actual measurement may be measurement by a measure or the like. In that case, you may measure a dimension using what was photographed.
- the fiber grain 2 has an air layer in the grain. Since the plurality of fibers 3 are entangled three-dimensionally, air exists in the gaps between the fibers 3. Therefore, elasticity is increased. Moreover, since the air is retained, a unique comfortable texture can be imparted to the fiber sheet 1. Moreover, since the fiber grain 2 has air, it is light. Furthermore, since the fiber grain 2 is a grain, it has bulkiness and high durability. Furthermore, the fiber grain 2 has moisture retention. Moreover, the fiber grain 2 is excellent in fluidity
- the fiber 3 can be either synthetic fiber or natural fiber.
- synthetic fibers include polyester fibers, polyolefin fibers, acrylic fibers, polyamide fibers, cellulose fibers, and polyphenylene sulfide (PPS) fibers.
- the fiber 3 is preferably a polyester fiber.
- the polyester fiber By using the polyester fiber, the fiber sheet 1 having excellent elasticity can be easily formed.
- the polyester include polyethylene terephthalate (PET) and polyethylene naphthalate (PEN).
- natural fibers include wool.
- the fiber grain 2 and the fiber sheet 1 formed of wool have high heat insulating properties. Further, the wool fiber sheet 1 can give a comfortable texture.
- the mixed fiber can also be used as the fiber 3.
- the mixed fiber is obtained as a mixed cotton.
- the fiber sheet 1 having a deodorizing property can be easily formed by blended cotton containing acrylic fibers.
- the elasticity and the like can be adjusted by using mixed cotton. Wool and synthetic fiber may be mixed.
- the fiber 3 a fiber whose inside is hollow can be used. Thereby, the elasticity can be further increased.
- the fiber grain 2 contains heat-weldable fibers. By including the heat-welding fibers, the fiber particles 2 can be easily bonded.
- the heat-weldable fiber functions as a binder.
- the proportion of the heat-weldable fiber in the entire fiber 3 is preferably in the range of 0.1 to 50% by mass. Thereby, adhesiveness can be improved, maintaining elasticity.
- the ratio of the heat-weldable fiber in the entire fiber 3 is more preferably in the range of 1 to 40% by mass.
- the fiber 3 constituting the fiber particle 2 may include a heat-weldable fiber and a fiber that is not heat-weldable or difficult to heat-weld. In addition, as long as the performance of the fiber sheet 1 can be ensured, all the fiber particles 2 may be formed of heat-weldable fibers.
- the fiber particle 2 preferably contains two or more polyester fibers having different melting points.
- the plurality of polyester fibers are classified into high-melting polyester fibers and low-melting polyester fibers.
- the melting point of the high melting point polyester fiber is higher than the melting point of the low melting point polyester fiber.
- the low melting point polyester fiber can be a heat-weldable fiber. Since the heat-weldable fiber has a low melting point, high strength adhesiveness can be easily obtained.
- the melting point of the heat-welding polyester fiber may be in the range of 100 to 160 ° C., for example. Thereby, adhesion becomes easy.
- the melting point of the low melting polyester fiber may be in the range of 110 to 150 ° C., for example.
- the melting point of the high melting point polyester fiber may be, for example, 10 ° C. higher than the melting point of the low melting point polyester fiber. Thereby, moldability increases.
- the melting point of the high melting polyester fiber may be in the range of 130 to 300 ° C., for example.
- the melting point of the high melting polyester fiber may be in the range of 150 to 250 ° C., for example.
- the fiber 3 is preferably a short fiber. When the fiber 3 is a short fiber, the fiber particle 2 is easily formed.
- the fiber length of the fiber 3 is preferably in the range of 2 to 100 mm. By using the fiber 3 having a length in this range, good elasticity can be imparted.
- the fiber length of the fiber 3 is more preferably in the range of 3 to 80 mm, and still more preferably in the range of 5 to 50 mm.
- the thickness (fineness) of the fiber 3 is preferably in the range of 1 to 40 denier. By using the fiber 3 having a thickness within this range, good elasticity can be imparted. Denier is a unit expressed in grams of 9000 meters of yarn mass. The actually measured diameter of the fiber 3 may be in the range of 10 to 200 ⁇ m, for example, but is not limited thereto. Micro-sized fibers are called microfibers. By using microfibers, high functionality can be imparted.
- the fiber 3 is preferably silicon-coated.
- the amount of silicon for the silicon coating may be small.
- the amount of silicon may be 0.0001 to 1 part by mass when the amount of fiber is 100 parts by mass. When the amount of silicon falls within this range, the entanglement of the fibers increases.
- the fiber grain 2 has a core portion in which the fibers 3 are closely entangled.
- the fibers 3 are densely arranged, and the ratio of the fibers 3 is large.
- an outer portion having a lower fiber ratio than the core portion is disposed. Due to the presence of the core portion, the fiber particles 2 are hard to be crushed because the particles are hard.
- the core portion 2P and the outer portion 2Q are shown. Further, the fibers 3 may exist uniformly in the fiber grain 2.
- the fiber particles 2 are attracted by the fibers 3 a that jump out to the periphery while maintaining the state of the fiber particles 2 to some extent.
- the fiber sheet 1 includes a granular portion 2A formed from the fiber particles 2 and a cotton-like portion 2B disposed around the granular portion 2A.
- the fiber particles 2 are drawn in a circle so that the structure can be easily understood, but the fiber particles 2 may be a lump of fibers 3.
- the part formed by the fiber grain 2 becomes the granular part 2A.
- the space between the fiber grains 2 is drawn with blanks so that the structure is easy to understand.
- the fibers 3a protruding from the fiber grains 2 are intertwined between the fiber grains 2. Are bonded together, whereby the fiber grain 2 is fixed.
- the part between the fiber grains 2 becomes the cotton-like part 2B.
- each of the fiber particles 2 is not an individual particle, and the fiber particles 2 are bonded to other fiber particles 2 arranged around the fiber sheet 2.
- the fibers 3 are curled and entangled.
- the fibers 3 are not rounded but are entangled in an irregular shape.
- the cotton-like part 2B is cotton-like.
- the amount of fibers in the granular portion 2A is larger than the amount of fibers in the cotton-like portion 2B. For example, when the object on the back side of the sheet is viewed through the fiber sheet 1, the cotton-like part 2B can be more visible than the granular part 2A. The cotton-like part 2B can see through.
- the fibers 3 entangled in the cotton-like part 2B are bonded by heat-weldable fibers. Therefore, the granular part 2 ⁇ / b> A and the cotton-like part 2 ⁇ / b> B are in close contact with each other, and the fiber grain 2 is prevented from coming off the fiber sheet 1. Thereby, the fiber sheet 1 with high adhesiveness and excellent strength is obtained.
- the fibers 3 a jumping out from one fiber particle 2 may enter another fiber particle 2. Thereby, adhesiveness further increases.
- the fiber 3 may be bonded by a heat-weldable fiber. Thereby, the strength is improved.
- the fiber sheet 1 Since the fiber sheet 1 has the granular portion 2A and the cotton-like portion 2B, it has a specific elasticity.
- the elasticity of the fiber sheet 1 can be expressed when a deforming force is applied. For example, when the fiber sheet 1 is pulled in a direction in which the fiber sheet 1 is expanded with a force that does not damage the fiber sheet 1, the amount of the cotton-like part 2B that spreads is larger than the granular part 2A. Further, when the fiber sheet 1 is crushed, the amount of shrinkage is larger in the cotton-like part 2B than in the granular part 2A. Thus, the expansion and contraction is not uniform due to the presence of the granular portion 2A and the cotton-like portion 2B. Therefore, excellent elasticity is imparted.
- the granular portion 2 ⁇ / b> A that is, the fiber particle 2
- the number of granular portions 2 ⁇ / b> A that is, fiber particles 2 included in the sample is approximately the same.
- the “substantially the same number” may mean that in a plurality of samples, the number of granular portions 2A included in the sample falls within a range of ⁇ 10% of the average value.
- the ratio of the number of fiber particles 2 in the fiber sheet 1 is preferably 10 to 100,000 in terms of a sheet having a length of 100 mm, a width of 100 mm, and a thickness of 10 mm (referred to as “unit sheet”). Thereby, the outstanding elastic force can be provided.
- the ratio of the number of fiber particles 2 in the fiber sheet 1 is more preferably, for example, 100 to 10,000 per unit sheet, and further preferably 200 to 1,000.
- the thickness of the fiber sheet 1 is preferably in the range of 5 to 100 mm. Thereby, handling of the fiber sheet 1 becomes easy.
- the thickness of the fiber sheet 1 is more preferably in the range of 10 to 50 mm.
- the fiber sheet 1 is preferably at least 300 mm long and 300 mm wide, more preferably 500 mm long and 500 mm wide. In the fiber sheet 1, even when it becomes large, excellent elasticity can be obtained.
- the thickness of the fiber sheet 1 is larger than the size of the fiber grain 2.
- the basis weight of the fiber sheet 1 can be appropriately changed depending on the application.
- the basis weight can be adjusted by adjusting the density of the fiber particles 2.
- the basis weight of the fiber sheet 1 can be set within a range of 10 to 10,000 g / m 2 , for example. Since the fiber sheet 1 contains air, it can be reduced in weight. Therefore, the handleability of the fiber sheet 1 can be improved.
- the air permeability of the fiber sheet 1 can be appropriately changed according to the application. In the fiber sheet 1, the air permeability can be adjusted by adjusting the density of the fibers 3.
- the air permeability of the fiber sheet 1 (the amount of air that passes through an area of 1 cm 2 per second when a certain pressure is applied to the sheet) can be in the range of 1 to 500 cm 3 / cm 2 ⁇ s, for example.
- the air permeability of the fiber sheet 1 is 5 cm 3 / cm 2 ⁇ s or less, a sheet with less air permeability can be provided.
- the air permeability of the fiber sheet 1 is 50 cm 3 / cm 2 ⁇ s or more, a highly air-permeable sheet can be provided.
- an air layer can be formed in the fiber sheet 1, heat insulation can be improved.
- the air permeability of the fiber sheet 1 can be measured with a Frazier type air permeability tester. It is preferable that the fiber sheet 1 can return to the original thickness when the compressive force is released after pressing the fiber sheet 1 in the thickness direction to compress the thickness to 50%. Thereby, the fiber sheet 1 excellent in elasticity can be obtained.
- the tensile strength of the fiber sheet 1 can be appropriately changed according to the application. In the fiber sheet 1, the tensile strength can be adjusted by the type and amount of the heat-weldable fiber.
- the tensile strength of the fiber sheet 1 can be in the range of 1 to 1000 N / 5 cm, for example. When the tensile strength is high, breakage of the fiber sheet 1 and dropping of the fiber particles 2 are suppressed, and the fiber sheet 1 having high strength can be obtained.
- the fiber sheet 1 may be formed long.
- the fiber sheet 1 may be formed so as to be wound up. If the fiber sheet 1 can be wound up, the productivity is improved.
- the lateral width (length in the short direction) of the fiber sheet 1 is preferably 500 mm or more, and preferably 1000 mm or more, for example.
- the lateral width of the fiber sheet 1 may be 3000 mm or less, for example. Thereby, manufacture becomes easy.
- the fiber sheet 1 has an air layer in the granular portion 2A and the cotton-like portion 2B. Since the plurality of fibers 3 are entangled three-dimensionally, air exists in the gap between the fiber sheets 1. Therefore, elasticity is increased. Furthermore, since the amount of the fibers 3 is different between the granular portion 2A and the cotton-like portion 2B, unique elasticity can be given. Moreover, since the granular part 2A and the cotton-like part 2B have air, the fiber sheet 1 can obtain a unique comfortable texture. For example, it is possible to obtain a feeling like a feather. Moreover, the fiber sheet 1 is light, bulky, and highly durable. Furthermore, the fiber sheet 1 has moisture retention. Moreover, since the fiber grain 2 has adhere
- the fiber sheet 1 has high pressure dispersibility. While the fiber particles 2 are subjected to pressure and the portion where the fibers 3 between the fiber particles 2 are entangled absorbs the pressure, the pressure dispersibility is higher than that of the sheet in which the fibers are simply three-dimensionally entangled. Therefore, the fiber sheet 1 is excellent as a material for bedding and cushions. The fiber sheet 1 has excellent elasticity while being swollen. The fiber sheet 2 is firmly bonded to the fiber grain 2. Moreover, the fiber sheet 1 is easy to return to the original shape even if it is crushed. Furthermore, the fiber sheet 1 is excellent in drying property. Therefore, it is also possible to wash with a household washing machine.
- the manufacturing method of the fiber sheet 1 includes the following steps.
- the fibers 3 are entangled to form a plurality of fiber particles 2; -Three-dimensionally arranging a plurality of fiber particles 2 into a sheet shape;
- the plurality of fiber particles 2 arranged three-dimensionally are heated, and the plurality of fiber particles 2 are bonded by the heat-weldable fibers contained in the plurality of fiber particles 2.
- the manufacturing method of the fiber sheet 1 can easily manufacture the fiber sheet 1 having the excellent characteristics described above. And the fiber sheet 1 can be manufactured efficiently.
- the manufacturing method of the fiber sheet 1 it is preferable to include the following process in order to arrange
- FIG. 3 is a schematic view showing an example of a method for manufacturing the fiber sheet 1.
- the manufacturing method will be described in more detail with reference to FIG.
- the process flow is indicated by white arrows.
- the flow of the fiber 3 is indicated by a solid thick arrow.
- the inside of the container is appropriately drawn so that the fibers 3 and the fiber particles 2 can be easily understood.
- raw cotton 10 is prepared.
- Raw cotton is cotton used as a raw material.
- a raw cotton is obtained by synthesizing the synthesized fiber.
- the fibers constituting the raw cotton 10 may be short fibers.
- the raw cotton 10 is opened. Opening loosens the entangled fibers.
- the fibers are separated by opening. However, the fibers do not have to be completely separated. If the fiber is opened to some extent, it is possible to proceed to the next step.
- the divided fibers 3 can be in a state where cotton is swollen.
- main raw cotton 10 and auxiliary raw cotton 10 may be prepared.
- the main raw cotton 10 is for constituting the main fibers 3 in the fiber sheet 1.
- the main raw cotton 10 may have a larger amount of fibers than the auxiliary raw cotton 10.
- the secondary raw cotton 10 can be composed of heat-weldable fibers.
- the main raw cotton 10 can be composed of fibers that are not heat-weldable or difficult to heat-weld.
- the fibers 3 opened from the main raw cotton 10 and the fibers 3 opened from the main raw cotton 10 are mixed. These fibers 3 are preferably mixed almost uniformly. Thereby, the heat-weldable fiber is blended in the fiber 3 in a suitable amount.
- Cotton in which a plurality of types of fibers 3 are mixed is called mixed cotton.
- Raw cotton 10 containing fibers 3 coated with silicon may be used. Silicon adheres to the surface of the fiber 3. When the fiber 3 is coated with silicon, the handleability of the fiber 3 is enhanced. Efficiency is increased by using raw cotton 10 formed of fibers that have been pre-coated with silicon. Silicon may be adhered to the opened fiber 3. When liquid silicon is used, silicon is deposited by spraying silicon. In that case, silicon can be more evenly adhered by spraying silicon while stirring the fibers 3. Silicon oil can be used as the silicon.
- the mixing of the fibers 3 can be performed by the fiber mixing device 11.
- the fiber mixing device 11 is a device that mixes the fibers 3 by stirring. Mixing is possible by the fiber mixing device 11. Stirring may be performed by a blade or air flow. In addition, you may perform the mixing of the silicon
- the fiber 3 is sent to the fiber grain forming device 12. Since the opened fiber 3 is light, it can be sent by air (air) flow. Between each apparatus from the fiber mixing apparatus 11 to the fiber grain arrangement
- the fiber grain forming device 12 includes two fiber grain forming devices 12.
- the fiber particle forming device 12 is defined as a first fiber particle forming device 12A and a second fiber particle forming device 12B in the order in which the fibers 3 flow.
- the fiber grain forming device 12 has a frustoconical container. In the frustoconical container, air rotates and flows. The air may rotate in a spiral. The air can flow in a tornado shape.
- the fiber 3 enters from above the fiber grain forming device 12. And the fiber 3 sent along the flow of air rotates three-dimensionally by rotation of the air in the fiber grain formation apparatus 12, is rounded, and becomes a grain shape.
- the fiber 3 may have a substantially spherical shape. In the container, the stirring blade may rotate.
- the fiber grain forming device 12 can cause air convection.
- the fiber 3 that has moved downward from above may move upward a plurality of times.
- the fiber 3 is easily rounded due to resistance.
- the fiber 3 may collide with the wall of the container. In this way, the fibers 3 coming out of the fiber particle forming device 12 become fiber particles 2.
- the fiber grain 2 exits from below the fiber grain forming device 12.
- the fiber particles 2 that have come out of the fiber particle forming device 12 enter the storage tower 13 that stores the fiber particles 2 once.
- the fiber particles 2 are stacked in the vertical direction and temporarily stored.
- the storage tower 13 is a particle reservoir. In this way, by storing the fiber particles 2, the fiber particles 2 can be sent to the next apparatus in a stable amount. Therefore, the favorable fiber sheet 1 with which the particle
- the fiber particles 2 enter the storage tower 13 from the upper part of the storage tower 13.
- the fiber particles 2 exit from the storage tower 13 at the lower part of the storage tower 13. In the storage tower 13, the fiber particles 2 enter from the upper part, and the fiber particles 2 exit from the lower part, and the fiber particles 2 are always stacked.
- the storage tower 13 serves as a reservoir.
- a first reservation tower 13A and a second reservation tower 13B are provided.
- the first storage tower 13A is disposed between the first fiber particle forming device 12A and the second fiber particle forming device 12B.
- the second storage tower 13B is disposed between the second fiber particle forming device 12B and the fiber particle arranging device 14.
- the presence of the first storage tower 13A stabilizes the amount of fiber particles 2 sent out to the second fiber particle forming device 12B.
- the second storage tower 13B the amount of the fiber particles 2 sent out to the fiber particle arranging device 14 is stabilized.
- the fibers 3 are easily collected. Therefore, in the example of FIG. 3, two fiber particle forming apparatuses 12 are used in order to obtain the fiber particles 2 having a well-formed shape.
- the first fiber particle forming device 12A the core of the fiber particle 2 is easily formed.
- the first fiber particle forming device 12 ⁇ / b> A can form the fiber particles 2 by rounding the disjoint fibers 3.
- the fiber particle 2 can be formed by entanglement of the fiber 3.
- the fiber particles 2 exiting the first fiber particle forming device 12A may be soft and the surroundings are blurred. Therefore, resistance is further applied to the fiber particles 2 and the fiber particles 2 are tightened by the second fiber particle forming device 12B.
- the second fiber particle forming device 12B can strengthen the entanglement of the fibers 3 in the fiber particles 2.
- the fibers 3 may be condensed by the second fiber grain forming device 12B. When the fibers in the fiber grain 2 are strongly tightened, the fiber grain 2 becomes strong.
- the fiber particle 2 that exits the second fiber particle forming device 12B is more solid than the fiber particle 2 before entering the second fiber particle forming device 12B.
- the fiber grain 2 may be hardened.
- the density of the fiber particles 2 may be increased.
- the degree of entanglement of the fibers in the fiber grain 2 may increase.
- the particle diameter of the fiber grain 2 may be small.
- the density of the fiber particles 2 exiting the second fiber particle forming device 12B can be, for example, 1.5 to 5 times higher than the density of the fiber particles 2 before entering the second fiber particle forming device 12B.
- the use of the plurality of fiber particle forming devices 12 increases the elasticity of the fiber particles 2.
- the number of fiber grain forming devices 12 may be three or more.
- a plurality of fiber particles 2 are formed by entanglement of the fibers 3 to form particles. As for the fiber grain 2, a part of fibers may protrude to the circumference.
- the fiber particle 2 that has come out of the second fiber particle forming device 12B enters the second storage tower 13B and is then sent to the next step.
- the fiber particles 2 are not limited to those obtained by the above method.
- the fiber grain 2 a suitable one in which the fiber 3 is granulated can be used.
- the fiber ball disclosed in Patent Document 1 may be used as the fiber particle 2.
- the fiber grain 2 may be a fiber ball.
- the fiber grain 2 is sent to the fiber grain placement device 14.
- the fiber particle arrangement device 14 is a device that three-dimensionally arranges the fiber particles 2 so as to have a sheet shape. Since the fiber grain 2 is light, it can be sent by the flow of air. When the fiber particles 2 are caused to flow by the flow of air, the fibers hit the fiber particles 2, and the fibers are likely to jump out around the particles while maintaining the state of the fiber particles 2. Therefore, adhesion of the fiber grain 2 becomes easy.
- the fiber grain placement device 14 includes a placement container 15.
- a gap 16 is provided in the arrangement container 15 at the bottom.
- the gap 16 may be a groove-like gap.
- the gap 16 is formed elongated.
- the gap 16 is formed between a plurality of rollers 17.
- a pair of two rollers 17a and 17b are drawn.
- the number of rollers 17 may be three or more.
- the plurality of rollers 17 are arranged in parallel.
- the direction in which the roller 17 extends may be the same as the width direction of the sheet of fiber particles 2 to be formed.
- the gap 16 may be the same as the width direction of the sheet of fiber particles 2 to be formed.
- the gap 16 may be along the longitudinal direction of the sheet.
- a plurality of gaps 16 may be provided.
- the gap 16 is formed so that the fiber grain 2 can pass therethrough.
- the rollers 17a and 17b can be rotated in the opposite directions. In the example of FIG. 3, the roller 17 can be rotated so that the roller 17 flows downward in the gap 16 between the two rollers 17 (see the broken line arrow).
- the plurality of rollers 17 may have a feeder function of pushing out the fiber particles 2. You may extrude the fiber grain 2 with a feeder.
- the roller 17 is an example of a feeder that passes the fiber particles 2 between the gaps 16, and a feeder having another structure may be used.
- the fiber grain 2 enters the placement container 15 from above. At this time, the fiber particles 2 may be washed away with air. The fiber particles 2 that have entered the placement container 15 fall downward due to the action of gravity. The fiber particles 2 that have fallen downward reach the vicinity of the roller 17. Then, the fiber grain 2 falls downward through the gap 16. When passing through the gap 16, the fiber particles 2 can fall evenly downward. Therefore, it becomes possible to arrange the fiber particles 2 uniformly in a three-dimensional shape. When the roller 17 rotates in the direction of dropping the fiber grain 2 downward, the fiber grain 2 is more likely to fall. The fiber grain 2 that has passed through the gap 16 exits from below the placement container 15.
- the gap 16 has such a size that the fiber particle 2 having an average particle diameter is caught in the gap 16. If the width of the gap 16 is too wide and the fiber particles 2 pass through the gap 16, the uniformity of the arrangement of the fiber particles 2 may be deteriorated. On the other hand, if the width of the gap 16 is too narrow, the fiber particles 2 may not easily enter the gap 16. The fiber particles 2 may be caught by fibers that have jumped out to the periphery, or may be caught by a physical force such as an electrostatic force.
- the width of the gap 16, that is, the dimension between the rollers 17 is preferably 50 to 200% of the average particle diameter of the fiber particles 2. When the width of the gap 16 is about this level, the uniformity of the arrangement of the fiber particles 2 is improved. More preferably, the width of the gap 16 is 70 to 150% of the average particle diameter of the fiber particles 2.
- the plurality of fiber particles 2 be taken out from the gap 16 after the plurality of fiber particles 2 are retained. If the fiber particles 2 are not retained, the fiber particles 2 are sent downward by the air flow while being sent from the pipe, and therefore there is a possibility that the fiber particles 2 cannot be arranged uniformly. However, if the fiber particle 2 is put out from the gap 16 after the fiber particle 2 is once held, the fiber particle 2 can be easily taken out of the arrangement container 15 from the gap 16 in a stable amount.
- the fiber particles 2 can be retained in the vicinity of the gap 16. For example, as shown in FIG. 3, when the roller 17 is provided, the fiber particle 2 is held once on the roller 17. The fiber particles 2 can be retained in the placement container 15. The fiber grain 2 may be held above the gap 16.
- the fiber grains 2 may be stacked in the vertical direction. Of the suspended fiber particles 2, the fiber particles 2 existing in the vicinity of the roller 17 are caused to flow downward through the gap 16 by the rotation of the roller 17. A portion where the fiber particles 2 in the arrangement container 15 are reserved is defined as a storage portion 18.
- the holding unit 18 is above the gap 16 and the roller 17. In addition, you may make it push in the fiber grain 2 hold
- the plurality of fiber particles 2 coming out of the arrangement container 15 are three-dimensionally arranged in a sheet shape.
- the plurality of fiber particles 2 that have come out below the arrangement container 15 can be arranged substantially evenly in the width direction and the thickness direction. And when the several fiber particle 2 flows, the fiber particle 2 may be arrange
- the plurality of fiber particles 2 arranged in three dimensions serves as a precursor of the fiber sheet 1.
- the plurality of fiber particles 2 arranged three-dimensionally in a sheet shape is defined as a sheet-like fiber particle 2S.
- an inclined portion 19 is provided below the arrangement container 15.
- the inclined portion 19 can be formed by making the passage through which the fiber particles 2 flow oblique.
- the inclined portion 19 may be formed by inclining the plate.
- the presence of the inclined portion 19 allows the sheet-like fiber particle 2S to flow while maintaining a three-dimensional shape.
- the sheet-like fiber particle 2S is continuously formed by flowing while sliding on the inclined portion 19.
- the inclination angle of the inclined portion 19 can be appropriately adjusted to an angle at which the fiber particles 2 in the sheet-like fiber particles 2S are not separated and the sheet-like fiber particles 2S can easily flow downward.
- the inclined portion 19 can be made of metal, for example.
- the fibers jumping out around may be entangled. Thereby, the fiber sheet 1 with high adhesiveness can be formed easily.
- positioning container 15, ie, the sheet-like fiber particle 2S has become a three-dimensional shape by the entanglement of a fiber, the connection of particle
- the sheet-like fiber particle 2S is preferably weighed.
- the amount of fibers is stabilized by weighing the sheet-like fiber particles 2S. By weighing, the weight per unit area of the sheet-like fiber particle 2S is measured.
- a predetermined standard can be set. For example, if the weight falls within a predetermined range (for example, ⁇ 10%) of the weight of the reference value, it is determined as a non-defective product, and if it falls outside the range, it is determined as a defective product.
- a predetermined range for example, if the weight falls within a predetermined range (for example, ⁇ 10%) of the weight of the reference value, it is determined as a non-defective product, and if it falls outside the range, it is determined as a defective product.
- the fiber sheet 1 in which the fiber grains 2 are arranged more evenly can be easily obtained.
- the metering is performed between the fiber grain placement device 14 and the heating device 20.
- the measurement is preferably performed while feeding the sheet-like fiber particles 2S.
- continuous metering can be performed by disposing the metering device 22 below the passage through which the sheet-like fiber particles 2S flow.
- the measuring device 22 can be disposed, for example, below the inclined portion 19.
- the measuring instrument 22 may be disposed in the middle of the inclined portion 19.
- FIG. 3 shows a state in which the sheet-like fiber particles 2S are weighed by the weighing instrument 22.
- the fiber particles 2 in the sheet-like fiber particle 2S are not adhered and can be easily separated.
- the sheet-like fiber particle 2S of that portion can be taken out, the fiber particle 2 can be separated, and the process can be returned to the step of arranging the fiber particle 2 again in a sheet shape. Therefore, waste of materials can be omitted. Further, it is preferable that feedback control is performed to adjust the supply amount of the fiber particles 2 in the fiber particle arranging device 14 so that the sheet-like fiber particles 2S are within a predetermined weight range by measurement.
- the weight of the sheet-like fiber particle 2S is smaller than a predetermined weight, the amount of the fiber particle 2 coming out of the fiber particle arranging device 14 is increased, and when the weight of the sheet-like fiber particle 2S is larger than the predetermined weight , Reduce the amount of fiber particles 2 exiting the fiber particle placement device 14.
- the uniformity in a conveyance direction will improve and the fiber sheet 1 with higher uniformity can be obtained.
- the sheet-like fiber particle 2S is sent to the heating device 20.
- the sheet-like fiber particle 2S may be sent by being pushed on the passage, or may be sent by a conveyor.
- the heating device 20 heats the sheet-like fiber particle 2S to a temperature at which the heat-weldable fibers exhibit weldability.
- the fibers are bonded by the heat-weldable fibers, and the plurality of fiber particles 2 are bonded and formed into a sheet shape.
- the heating device 20 may pass the gap formed by the rolls 21 while heating the sheet-like fiber particles 2S.
- the thickness of the fiber sheet 1 is adjusted by the size of the gap formed by the roll 21.
- the gap formed by the rolls 21 can be formed between the opposed rolls 21 or can be formed between the rolls 21 and the conveyor. In FIG.
- the example of the roll 21 which opposes is shown.
- the pressing force by the roll 21 may be weak.
- the sheet-like fiber particle 2S may be pressed, and in that case, the thickness of the fiber sheet 1 can be adjusted by the space formed by the press.
- the sheet-like fiber particle 2S may be heated as it is without applying a physical force because there is no roll 21 or no press. In this way, the plurality of fiber particles 2 arranged three-dimensionally are heated, and the plurality of fiber particles 2 are bonded by the heat-weldable fibers. Adhesion can be performed at a portion where the fibers 3a that protrude to the periphery come into contact with other fibers.
- the fibers 3 in the fiber grain 2 may be bonded together. Adhesion is possible when the fibers 3 that come into contact contain heat-weldable fibers.
- the fiber sheet 1 When the fiber sheet 1 is continuously formed, the fiber sheet 1 can be arranged in an appropriate shape.
- the fiber sheet 1 may be wound up or cut.
- the fiber sheet 1 in the case of a relatively thin sheet, the fiber sheet 1 can be sent out and wound up.
- a rolled fiber sheet 1 ⁇ / b> R is drawn as the wound fiber sheet 1.
- the roll-shaped fiber sheet 1R can be used for applications that require deformability and flexibility, such as clothes.
- the fiber sheet 1 since the fiber particles 2 are firmly bonded, the fiber particles 2 are not easily dropped even if they are wound up.
- productivity In the case of a relatively thick sheet, the fiber sheet 1 can be cut into an appropriate size.
- the cut fiber sheet 1 can be plate-shaped. In FIG.
- a plate-like fiber sheet 1 ⁇ / b> B is drawn as the cut fiber sheet 1.
- the plate-like fiber sheet 1B can be used for a core material of a mattress, for example.
- the fiber sheet 1 since the fiber particles 2 are firmly bonded, the fiber particles 2 are not easily dropped even if the cutting is performed.
- the handleability is improved.
- the fiber sheet 1 can be continuously manufactured from the raw cotton 10. Continuous production improves production efficiency.
- the fiber 3 continuously opened from the raw cotton 10 can be formed.
- Fiber grains 2 can be formed continuously from the fibers 3.
- the sheet-like fiber particle 2S can be continuously formed from the fiber particle 2.
- the fiber sheet 1 can be continuously formed from the sheet-like fiber particles 2S.
- FIG. 4 illustrates a more preferable aspect of the fiber grain placement device.
- FIG. 4 is a schematic configuration diagram showing the fiber grain placement device 50.
- FIG. 4 consists of FIGS. 4A and 4B. 4A is a side view and FIG. 4B is a front view.
- the fiber particle arrangement device 50 described below can be replaced with the fiber particle arrangement device 14 described above. Therefore, in FIG. 4, the same reference numerals are written in parentheses for the configuration corresponding to the configuration described above. For example, it is described as “fiber grain arrangement device 50 (14)”.
- the flow of air is indicated by white arrows
- the flow of fiber particles is indicated by block arrows with diagonal lines
- the movement of mechanical parts (such as rollers) is indicated by arrows.
- the fiber particle arranging device 50 is a device that three-dimensionally arranges a plurality of fiber particles 2 into a sheet shape.
- the fiber grain arrangement device 50 includes a supply duct 51, an exhaust duct 52, a storage unit 53, a supply roller 55, a distribution roller 56, a holding unit 57, a carry-out roller 60, a carry-out plate 61, and a fan 62.
- the control unit 63 and the input / output unit 64 are provided.
- the supply duct 51 is an air flow path for flowing the fiber particles 2 sent from the upstream storage tower 13 (see FIG. 3).
- the exhaust duct 52 is an air flow path for exhausting the air flowing from the supply duct 51. Air flows from the supply duct 51 and flows out to the exhaust duct 52 as the entire fiber grain placement device 50. However, part of the air flows toward the distribution roller 56.
- the fiber particles 2 entering from the supply duct 51 are flowed downward and stored in the storage unit 53.
- the storage unit 53 can stabilize the supply amount of the fiber particles 2 by storing (holding) the fiber particles 2 once. Further, the storage unit 53 can block the air pressure of the supply duct 51 so as not to adversely affect the three-dimensional arrangement of the fiber particles 2.
- the reservoir 53 is provided with an upper air outlet 54.
- the upper air discharge port 54 is constituted by a perforated plate, for example. By having the upper air discharge port 54, the supplied air can be smoothly exhausted, and excessive pressure can be prevented from being applied to the inside of the apparatus.
- the fiber particles 2 that have entered the storage unit 53 are sent downstream by the supply roller 55.
- the fiber particle 2 flows toward the distribution roller 56 by the rotation of the supply roller 55.
- the supply roller 55 is electrically connected to the control unit 63.
- the rotation speed of the supply roller 55 can be adjusted by the control of the control unit 63.
- the control unit 63 can be configured by an electric circuit. By changing the rotation speed of the supply roller 55, the amount of the fiber particles 2 sent out from the supply roller 55 is adjusted. When the rotation speed is increased, the amount of the fiber particles 2 to be sent out increases, and conversely, when the rotation speed is reduced, the amount of the fiber particles 2 to be sent out decreases.
- the supply roller 55 may be provided with a scraping portion 55a.
- the scraping portion 55a can scratch and send out the fiber particles 2.
- the scraping portion 55 a can be formed of a jagged protrusion provided on the outer periphery of the supply roller 55. Further, the scraping portion 55a may be formed by providing a wire on the supply roller 55, for example.
- the distribution roller 56 has a function of distributing the plurality of fiber particles 2 fed from the supply roller 55 along the width direction of the fiber sheet 1.
- the width direction of the fiber sheet 1 is the same as the axial direction (longitudinal direction) of the distribution roller 56.
- the distribution roller 56 may rotate at a constant speed.
- the diameter of the distribution roller 56 may be larger than the diameter of the supply roller 55.
- the distribution roller 56 includes a plurality of protruding rods 56a.
- the plurality of protruding rods 56a are arranged on the outer periphery of the distribution roller 56 at equal intervals in the circumferential direction (FIG.
- the fiber particles 2 in the direction along the axial direction of the distribution roller 56 becomes more uniform. Since the fiber particles 2 distributed by the distribution roller 56 tend to flow to a portion having a low flow resistance, the fiber particles 2 are automatically directed to a portion where the amount of the fiber particles 2 in the retaining portion 57 is small.
- the fiber particles 2 that have passed through the distribution roller 56 enter the holding unit 57.
- the holding unit 57 holds the fiber particles 2 sent out from the distribution roller 56.
- the holding unit 57 corresponds to the holding unit 18 in FIG. Since the fiber particle 2 is once retained in the retaining part 57, the fiber particle 2 can be stably disposed.
- the holding part 57 is provided with a lower air discharge port 58.
- the lower air discharge port 58 is constituted by a perforated plate, for example. By having the lower air discharge port 58, the air flowing into the holding unit 57 is smoothly exhausted, and it is possible to suppress an excessive pressure from being applied to the holding unit 57.
- the lower air discharge port 58 is connected to the internal air passage 59, and the air flows to the internal air passage 59.
- the fiber grain arranging device 50 further includes a sheet width adjusting body 66 as shown in FIG. 4B.
- the sheet width adjusting body 66 is provided in the holding portion 57.
- the presence of the sheet width adjusting body 66 makes it easy to adjust the width of the fiber sheet 1.
- the sheet width adjusting body 66 includes a pair of sheet width adjusting portions 66a.
- the pair of sheet width adjustment portions 66a can be moved closer or away. When the pair of sheet width adjusting parts 66a approaches, the width of the fiber sheet 1 can be reduced, and when the pair of sheet width adjusting parts 66a move away, the width of the fiber sheet 1 can be increased.
- the sheet width adjusting body 66 can be configured to gradually narrow the space of the retaining portion 57 from upstream to downstream.
- the fiber particles 2 held in the holding unit 57 are unloaded from the holding unit 57 through the pair of unloading rollers 60.
- the carry-out roller 60 corresponds to the roller 17 in FIG.
- a gap 16 similar to that described above is provided between the pair of carry-out rollers 60. Therefore, the fiber particles 2 can be efficiently and satisfactorily arranged three-dimensionally.
- the gap 16 defines the approximate thickness of the fiber sheet 1.
- the gap 16 can be, for example, in the range of 5 to 100 mm.
- the fiber grain placement device 50 includes an internal air passage 59 for circulating air.
- the internal air passage 59 is connected to both the upstream side and the downstream side of the retaining portion 57.
- a fan 62 is provided in the internal air passage 59.
- An air flow can be created in the internal air passage 59 by the fan 62.
- the fan 62 is electrically connected to the control unit 63.
- the control unit 63 controls the rotation of the fan 62.
- the rotation speed of the fan 62 changes the speed of air flow in the internal air passage 59.
- the pressure in the holding part 57 also changes.
- the air that has exited from the retaining portion 57 through the lower air discharge port 58 rises, and this air can enter above the retaining portion 57 (below the distribution roller 56). .
- the control unit 63 can control the amount of fiber particles 2 in the holding unit 57.
- the control unit 63 is configured to be able to adjust the pressure of the holding unit 57 to a predetermined pressure.
- the control unit 63 is electrically connected to the supply roller 55 and can control the rotation speed of the supply roller 55.
- the control unit 63 is electrically connected to the pressure sensor 65 provided in the holding unit 57 and the fan 62. Accordingly, the control unit 63 can control the fan 62 based on the pressure detected by the pressure sensor 65 so that the pressure of the holding unit 57 becomes a predetermined value (set value).
- the control unit 63 is electrically connected to the carry-out roller 60 and can control the rotation speed of the carry-out roller 60.
- the carry-out amount of the fiber particles 2 can be adjusted, and the fiber particles 2 can be arranged satisfactorily.
- the carry-out roller 60 may be configured to freely rotate. In that case, the fiber particle 2 can be pushed downward by the air pressure of the holding portion 57 and can pass between the carry-out rollers 60.
- the rotation speed of the carry-out roller 60 can be monitored by the control unit 63.
- the control unit 63 can adjust the rotation speed of the supply roller 55 and the pressure of the holding unit 57 to adjust the amount of the fiber particles 2 going in and out. .
- the control unit 63 may control the rotation speed of the supply roller 55 so as to prevent excessive fiber particles 2 from entering the holding unit 57. it can. As a result, the pressure of the holding unit 57 is reduced and returned to an appropriate value.
- the control unit 63 controls the supply roller 55 to increase the rotation speed so that the fiber particles 2 are retained. 57 may be supplied. Thereby, it can suppress that the fiber grain 2 is deficient in the holding
- the input / output unit 64 is a part for exchanging information between the outside and the inside.
- the input / output unit 64 includes an input unit and an output unit.
- the input unit includes switches, buttons, knobs, channels, and the like.
- the output unit includes a meter, a digital display, a display, and the like. For example, when a predetermined rotation speed is input, the supply roller 55 rotates at the rotation speed and sends the fiber particles 2 downstream.
- the fiber particle 2 sent out from the carry-out roller 60 becomes a sheet-like fiber particle 2S and is placed on the carry-out plate 61.
- the carry-out plate 61 has an inclined portion 19.
- the sheet-like fiber particle 2S is sent to the heating device 20 (see FIG. 3).
- the sheet-like fiber particle 2S is preferably weighed by the weighing instrument 22 (see FIG. 3). Then, it is preferable that feedback control is performed to adjust the supply amount of the fiber particles 2 in the fiber particle arranging device 50 so that the sheet-like fiber particles 2S are within a predetermined weight range by measurement. For example, when the weight of the sheet-like fiber particle 2S is smaller than a predetermined weight, the rotational speed of the supply roller 55 and / or the carry-out roller 60 is increased to increase the amount of the fiber particle 2 exiting from the fiber particle arranging device 50. Can do.
- the rotational speed of the supply roller 55 and / or the carry-out roller 60 is decreased to reduce the amount of the fiber particle 2 exiting from the fiber particle arranging device 50. Can do. By performing feedback control, a more uniform fiber sheet 1 can be obtained.
- the fiber particle placement device 50 includes the storage unit 53 that holds the plurality of fiber particles 2, the supply roller 55 that sends out the stored plurality of fiber particles 2, and the plurality of fiber particles 2 that are sent out from the supply roller 55.
- a distribution roller 56 that distributes the fibers along the width direction of the fiber sheet, a storage unit 57 that stores the plurality of fiber particles 2 fed from the distribution roller 56, and a plurality of fiber particles 2 that are stored in the storage unit 57.
- a pair of carry-out rollers 60 The gap 16 is provided between the pair of carry-out rollers 60. Therefore, the fiber particles 2 can be made uniform and arranged, and a good fiber sheet can be formed.
- the fiber sheet 1 can be considered to fall within the category of non-woven fabrics in the sense that it is not a woven fabric, but has completely different properties from conventional non-woven fabrics.
- the fiber sheet 1 has many voids.
- the fiber sheet 1 has a granular portion (granular portion 2A) and a cotton-like portion (cotton-like portion 2B), which are in close contact by adhesion. Therefore, as described above, unique operational effects that cannot be considered with conventional fibers can be obtained.
- the fiber sheet 1 can be used for bedding and cushions.
- bedding can be provided by using the fiber sheet 1 as a core and attaching a cover.
- the fiber sheet 1 has good pressure dispersibility.
- the fiber sheet 1 can be used for clothing.
- the fiber sheet 1 has a structure having the fiber grains 2 therein, various developments are possible. For example, it can be used for a seat mat of a vehicle such as an automobile, a train, a train, a ship, and an airplane.
- a material that is as light as possible is required.
- the fiber sheet 1 is preferable because it is light and strong.
- the fiber sheet 1 can be put in water and plant seeds can be used for agricultural applications such as hydroponics.
- the fiber sheet 1 can be used for medical purposes.
- the fiber sheet 1 has heat insulation and is excellent in sound absorption, it can be used for building materials, for example.
- fiber particles were produced from polyester short fibers.
- the fiber sheet was produced by arranging the fiber particles in a sheet shape and heating.
- FIG. 5A is a photograph of fiber grains.
- FIG. 5B is a photograph of the fiber sheet. As shown in FIG. 5B, the fiber sheet includes a plurality of fiber grains. It was confirmed that this fiber sheet exhibits a specific elastic force different from that of a sheet in which fibers are entangled three-dimensionally.
- examples of the high repulsion fiber particle (Granule example 1), the low repulsion fiber particle example (Granule example 2), and the fiber particles produced by the conventional method are used as the fiber particles.
- Four types of examples (granular example 3) and examples of commercially available fiber grains (granular example 4) were prepared, and their structures (fiber state of the fiber grains) were compared by the following method.
- the image of the fiber grain is converted into a gray scale by image processing.
- the grayscaled image is inserted into a two-dimensional cell matrix, and a value (gray value) determined by 256 gray levels from black 0 to white 255 is assigned to each cell. For the assigned gray value, the standard deviation of the average value of the row and column is obtained from the average value of the row and column, and further the average value of the standard deviation is obtained.
- Table 1 shows the results of the fiber grains of the grain examples 1 to 4 obtained by the above method.
- FIG. 6 is a graph showing standard deviations of gray values for four types of fiber grain examples. It can be said that the smaller the standard deviation, the more uniformly the fibers in the fiber grain.
- Grain examples 1 and 2 are uniform fiber grains with a standard deviation of 9 or less.
- the standard deviation of grain example 3 exceeds 9, and the uniformity is inferior to that of grain examples 1 and 2.
- the standard deviation of the example 4 exceeds 11, the uniformity is further inferior.
- the more uniform the fiber grain the more preferable the elasticity of the fiber sheet.
- the fiber sheets of Example 1 and 2 were superior in elasticity to the fiber sheets of Example 3 and 4.
- the standard deviation of the gray value is 9 or less. It can be seen that it is preferable. The smaller the standard deviation, the better.
- the lower limit of the gray value is ideally 0, but 1 may be 1 in consideration of reality.
- FIG. 7 is an example of a photograph of the above four types of fiber particles.
- FIG. 7 is composed of FIGS. 7A to 7D.
- FIG. 7A shows the fiber grain (2p) of grain example 1.
- FIG. 7B shows the fiber particles (2q) of Example 2.
- FIG. 7C shows the fiber grain (2r) of the grain example 3.
- FIG. 7D shows the fiber particles (2 s) of Example 4.
- the fiber grains of the grain examples 1 and 2 are denser in the center part than the fiber grains of the grain examples 3 and 4. Therefore, in the grain examples 1 and 2, it can be said that the fiber grain has a core portion in which the fibers are closely entangled.
- the fiber grains having a core have a structure like a golf ball having a core inside, not a hollow ping-pong ball.
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Abstract
Description
・繊維3を絡めて粒状にして複数の繊維粒2を形成する;
・複数の繊維粒2をシート形状になるよう立体的に配置させる;
・立体的に配置された複数の繊維粒2を加熱し、複数の繊維粒2に含まれる熱溶着性の繊維によって複数の繊維粒2を接着する。
・複数の繊維粒2を保留する;
・複数の繊維粒2を隙間16から出す。
上記で説明した方法に準じて、ポリエステル短繊維から繊維粒を作製した。繊維粒をシート形状に配置し、加熱することにより繊維シートを作製した。
Claims (7)
- 繊維が絡まって形成された複数の繊維粒を備え、
前記複数の繊維粒は、周囲に飛び出した繊維によって立体的に絡まっており、
前記複数の繊維粒は、前記複数の繊維粒に含まれる熱溶着性の繊維によって接着されている、繊維シート。 - 前記繊維粒の平均粒径は1~50mmの範囲内である、請求項1に記載の繊維シート。
- 前記繊維シートの厚みは5~100mmの範囲内である、請求項1又は2に記載の繊維シート。
- 前記繊維粒は、前記繊維が密に絡まったコア部を備えている、請求項1乃至3のいずれか1項に記載の繊維シート
- 繊維を絡めて粒状にして複数の繊維粒を形成することと、
前記複数の繊維粒をシート形状になるよう立体的に配置させることと、
立体的に配置された前記複数の繊維粒を加熱し、前記複数の繊維粒に含まれる熱溶着性の繊維によって前記複数の繊維粒を接着することと、を含む、繊維シートの製造方法。 - 前記複数の繊維粒をシート形状になるように立体的に配置させることは、
前記複数の繊維粒を保留することと、
前記複数の繊維粒を隙間から出すことと、を含む、請求項5に記載の繊維シートの製造方法。 - 前記複数の繊維粒をシート形状になるように立体的に配置させることは、繊維粒配置装置によって行われ、
前記繊維粒配置装置は、前記複数の繊維粒を貯留する貯留部と、貯留した前記複数の繊維粒を送り出す供給ローラと、前記供給ローラから送り出された前記複数の繊維粒を前記繊維シートの幅方向に沿って分配する分配ローラと、前記分配ローラから送り出された前記複数の繊維粒を保留する保留部と、前記保留部に保留された前記複数の繊維粒を搬出する一対の搬出ローラとを備え、前記隙間は、前記一対の搬出ローラの間に設けられている、請求項6に記載の繊維シートの製造方法。
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JP6156956B2 (ja) | 2017-07-05 |
CN106460269B (zh) | 2019-01-04 |
JP5957162B1 (ja) | 2016-07-27 |
TWI586506B (zh) | 2017-06-11 |
CN106460269A (zh) | 2017-02-22 |
KR20170004016A (ko) | 2017-01-10 |
JPWO2016035255A1 (ja) | 2017-04-27 |
TW201611976A (en) | 2016-04-01 |
KR101883419B1 (ko) | 2018-07-30 |
JP2016094692A (ja) | 2016-05-26 |
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