WO2020059267A1 - 不織布製造方法及び設備 - Google Patents
不織布製造方法及び設備 Download PDFInfo
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- WO2020059267A1 WO2020059267A1 PCT/JP2019/027777 JP2019027777W WO2020059267A1 WO 2020059267 A1 WO2020059267 A1 WO 2020059267A1 JP 2019027777 W JP2019027777 W JP 2019027777W WO 2020059267 A1 WO2020059267 A1 WO 2020059267A1
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- nonwoven fabric
- rotating
- collector
- conductor
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/0007—Electro-spinning
- D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
- D01D5/0076—Electro-spinning characterised by the electro-spinning apparatus characterised by the collecting device, e.g. drum, wheel, endless belt, plate or grid
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/04—Dry spinning methods
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/728—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by electro-spinning
Definitions
- the present invention relates to a nonwoven fabric manufacturing method and equipment.
- non-woven fabric formed of a so-called fiber having a nano-order diameter of several nm or more and less than 1000 nm.
- a method for producing a nonwoven fabric formed of such extremely thin fibers a method utilizing an electrospinning method (also referred to as an electrospinning method or an electrodeposition method) is known. This method is performed using, for example, an electrospinning apparatus having a nozzle, a collector, and a voltage application unit, and a voltage is applied between the nozzle and the collector by the voltage application unit. Thereby, for example, the nozzle is charged positively and the collector is charged negatively.
- a solution in which a fiber material (hereinafter, referred to as a fiber material) is dissolved in a solvent is discharged from the nozzle opening.
- the solution exiting the nozzle forms fibers while being attracted to the collector, which fibers are collected on the collector as a nonwoven.
- the fiber material dissolved in the solution may be solidified at the above-mentioned opening, and the opening may be closed. Therefore, there is a limit to the time for continuously forming the fiber. As a result, there is a limit in continuously producing a nonwoven fabric.
- Patent Document 1 describes that in the electrospinning method, the adhesive force between the nonwoven fabric and the collector can be adjusted by adjusting the distance between the portion from which the solution projects and the collector. .
- Patent Document 1 discloses that a rotating member composed of a rotating shaft and a disk is brought into contact with a solution in which a fiber material is dissolved, and the rotating member is rotated so that the entire side surface of the disk is coated with the solution. I have. Further, a technique for causing a solution to fly from a rotating member is also described in Patent Document 2.
- JP 2014-227629 A Japanese Patent Publication No. 2007-505224
- Patent Document 1 and Patent Document 2 have an advantage in that the fiber can be continuously used for a long time because a nozzle is not used.
- an object of the present invention is to provide a nonwoven fabric manufacturing method and equipment for improving the peelability from a collector and for continuously manufacturing a nonwoven fabric for a longer time.
- the method for producing a nonwoven fabric according to the present invention includes a first layer forming step, a second layer forming step, and a stripping step, in which a long collector is moved in a longitudinal direction, and a charge containing a polymer and a solvent is charged.
- the resulting solution is attracted to a collector charged to a polarity opposite to that of the solution or to a potential of zero, thereby collecting the polymer-formed fiber as a nonwoven fabric.
- the first layer forming step rotates while contacting the first solution disposed below the collector, and charges the first solution by the first rotating conductor formed of a conductor, thereby providing the moving collector with A first layer composed of a first fiber is formed.
- the second layer forming step rotates while contacting the second solution disposed below the collector downstream of the first solution in the moving direction of the collector, and the second rotating conductor formed of the conductor rotates the second solution.
- the second layer composed of the second fiber is formed in a state of being superimposed on the first layer.
- the nonwoven fabric including the first layer and the second layer is peeled from the collector.
- the first solution has a higher concentration of polymer than the second solution.
- the difference between the concentrations of the first solution and the second solution is preferably at least 1%.
- the first rotating conductor and the second rotating conductor have the same distance from the collector.
- first rotating conductor and the second rotating conductor have the same potential difference with the collector.
- the first rotating conductor preferably has a constant distance from the center of rotation to the periphery.
- the first rotating conductor includes a plurality of protrusions on the peripheral edge, and the vertices of the plurality of protrusions have the same distance from the center of rotation.
- the polymer is at least one of cellulose triacetate, cellulose diacetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, nitrocellulose, ethylcellulose, and carboxymethylethylcellulose. preferable.
- the solvent preferably contains at least one of dichloromethane, chloroform, methyl acetate and acetone.
- the nonwoven fabric manufacturing equipment of the present invention includes a long collector, a moving mechanism, a first container, a first rotating conductor, a second container, a second rotating conductor, a potential difference generator, and a polymer and a solvent. Is attracted to a collector charged to the opposite polarity to the solution or to a potential of zero, thereby collecting the polymer-formed fiber as a nonwoven fabric.
- the moving mechanism moves the collector in the longitudinal direction.
- the first container contains the first solution and is disposed below the collector.
- the first rotating conductor rotates while contacting the first solution, and is formed of a conductor.
- the second container contains the second solution, and is disposed downstream of the first container in the moving direction of the collector and below the collector.
- the second rotating conductor rotates while contacting the second solution in the second container, and is formed of a conductor.
- the potential difference generator causes a potential difference between the first rotating conductor and the second rotating conductor and the collector.
- the first solution has a higher polymer concentration than the "second" solution.
- the peelability from the collector can be improved, and the nonwoven fabric can be manufactured continuously for a longer time.
- FIG. 1 is a schematic view of a nonwoven fabric manufacturing equipment 10 according to one embodiment of the present invention, which is for continuously manufacturing a nonwoven fabric 11.
- the nonwoven fabric 11 can be used as, for example, a wiping cloth, a filter, or a medical nonwoven fabric (called a drape) applied to a wound or the like.
- the nonwoven fabric 11 is formed of two types of nanofibers 12 having different diameters from each other, and has a two-layer structure in which the first layer 11a and the second layer 11b overlap in the thickness direction.
- the first layer 11a is made up of one first fiber 12a having a relatively large diameter.
- the second layer 11b is composed of a second fiber 12b having a relatively small diameter. When the first fiber 12a and the second fiber 12b are not distinguished, they are collectively referred to as a nanofiber 12.
- the first layer 11a is formed directly on the surface of a charging belt 13 described later, and the second layer 11b is formed on the surface of the first layer 11a opposite to the charging belt 13 side. In this example, only one layer of the second layer 11b overlaps the first layer 11a, but another layer may be formed on the surface of the second layer 11b.
- the nonwoven fabric is not limited to such a two-layer structure, and may be formed of, for example, three or more types of nanofibers 12 having different diameters.
- the charging belt 13 is an example of a collector that collects the nanofibers 12 as the nonwoven fabric 11.
- the charging belt 13 is formed to be long, in this example, an annular endless belt, and moves in the longitudinal direction. After the manufactured nonwoven fabric 11 is peeled off from the charging belt 13, it is used for each of the above-mentioned applications.
- the first fiber 12a has a diameter Da within a range of greater than 1 ⁇ Db and 3 ⁇ Db or less, where Db is the diameter of the second fiber 12b.
- the diameter Db of the second fiber 12 is preferably in the range of 50 nm or more and 3000 nm or less.
- the nanofibers 12 are formed by electrospinning from a solution in which a polymer as a nanofiber material is dissolved in a solvent.
- the solution for forming the first fiber 12a is referred to as a first solution 16, and the solution for forming the second fiber 12b is referred to as a second solution 17.
- the nonwoven fabric manufacturing equipment 10 includes a first container 21 that stores the first solution 16 and a second container 22 that stores the second solution 17.
- the first container 21 and the second container 22 are arranged below the charging belt 13.
- the second container 22 is disposed downstream of the first container 21 in the moving direction of the charging belt 13. Therefore, the second solution 17 is located downstream of the first solution 16 in the moving direction of the charging belt 13.
- a thermoplastic resin is preferable, and among them, a cellulosic polymer is preferable.
- Cellulose-based polymers include cellulose triacetate (hereinafter referred to as TAC), cellulose diacetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, nitrocellulose, ethyl cellulose, and carboxymethyl ethyl cellulose.
- TAC cellulose triacetate
- cellulose diacetate cellulose propionate
- cellulose butyrate cellulose acetate propionate
- nitrocellulose ethyl cellulose
- carboxymethyl ethyl cellulose carboxymethyl ethyl cellulose.
- a solvent that evaporates relatively easily can be used, so that the degree of freedom of the diameter of the nanofiber 12 that can be formed is large.
- the nanofibers 12 having a small diameter (thin) can be formed similarly to other polymers, and the nanofibers 12 having a large diameter (thick) can be easily formed. Therefore, it is easy to manufacture the nonwoven fabric 11 according to the application. In addition, when these polymers are used, the improvement of the peelability described later from the charging belt 13 is more remarkable.
- the polymers contained in the first solution 16 and the second solution 17 may be the same or different. In this example, the same polymer is used for the first solution 16 and the second solution 17.
- the solvent contained in the first solution 16 and the second solution 17 is not particularly limited as long as it is a liquid compound that can dissolve a polymer as a fiber material.
- a solvent that evaporates easily even at a relatively low temperature from the viewpoint that the diameter of the nanofiber 12 can be adjusted to be small or large.
- Examples of such a solvent include at least any of dichloromethane (hereinafter, referred to as DCM), chloroform, methyl acetate, and acetone.
- the solvent may be a mixture of a plurality of compounds.
- the mixture a mixture obtained by mixing at least one of DCM, chloroform, methyl acetate, and acetone, methanol (hereinafter, referred to as MeOH), ethanol, and N, N-dimethylformamide is preferable.
- MeOH methanol
- the solvent is preferably a mixture from the viewpoint of easily adjusting the evaporation rate of the first solution 16 and the second solution 17 that have flown as described later.
- the solvents of the first solution 16 and the second solution 17 may be the same or different.
- the solvent of the first solution 16 and the solvent of the second solution 17 preferably contain a common component.
- the solvent of the first solution 16 and the solvent of the second solution 17 are a mixture, and have the same formulation (components and the mixing ratio of each component).
- the first solution 16 has a higher polymer concentration than the second solution 17.
- the difference in polymer concentration between the first solution 16 and the second solution 17 is at least 1%, that is, 1% or more.
- the difference in polymer concentration is more preferably in the range of 1% to 10%, and even more preferably in the range of 1% to 5%.
- the nonwoven fabric manufacturing equipment 10 includes a first rotating conductor 23 and a second rotating conductor 24 formed of a conductor.
- the first rotating conductor 23 and the second rotating conductor 24 are for charging the first solution 16 and the second solution 17 and flying them in a thread shape.
- the first rotating conductor 23 and the second rotating conductor have a rotating mechanism 27.
- the first rotating conductor 23 is provided in the first container 21 whose upper part is open.
- the first rotating conductor 23 has a rotating shaft 23a rotated by a rotating mechanism 27a, and a perfect circular disk 23b fixed to the rotating shaft 23a.
- a circular opening 23o is formed at the center of the disk 23b, and the opening 23o and the rotating shaft 23a are fixed in a fitted state.
- the disk 23b rotates in the circumferential direction integrally with the rotation shaft 23a.
- the disk 23b is arranged in a state where at least a part of the peripheral edge thereof comes out of the liquid surface of the first solution 16.
- the first rotating conductor 23 rotates while being in contact with the first solution 16.
- the periphery of the disk 23b that has come out of the liquid surface of the first solution 16 is in a state where the first solution 16 is attached.
- Both the rotating shaft 23a and the disk 23b are formed of a conductor, and the rotating shaft 23a is connected to the voltage applying unit 28.
- the voltage applying unit 28 When a voltage is applied by the voltage applying unit 28, the first solution 16 is charged to the first polarity.
- the number of the first rotating conductors 23 in this example is one, but a plurality of the first rotating conductors 23 may be arranged in the moving direction of the charging belt 13.
- a plurality of first rotating conductors 23 may be arranged in one first container 21 or a plurality of first containers 21 are arranged in the moving direction of the charging belt 13.
- the first rotating conductor 23 may be provided in each of the first containers 21.
- the second rotating conductor 24 is provided in the second container 22 whose upper part is open.
- the second rotating conductor 24 is configured similarly to the first rotating conductor 23, that is, has a rotating shaft 24a rotated by a rotating mechanism 27a and a perfect circular disk 24b fixed to the rotating shaft 24a.
- a circular opening 24o is formed at the center of the disk 24b, and the opening 24o and the rotating shaft 24a are fixed in a fitted state.
- the disk 24b rotates in the circumferential direction integrally with the rotation shaft 24a.
- the disk 24b is arranged in a state where at least a part of the peripheral edge thereof comes out of the liquid surface of the second solution 17.
- the second rotating conductor 24 rotates while being in contact with the second solution 17.
- the periphery of the disk 24b that has come out of the liquid surface of the second solution 17 is in a state where the second solution 17 is attached.
- Both the rotating shaft 24a and the disk 24b are formed of conductors, and the rotating shaft 24a is connected to the voltage applying unit 28.
- the rotating shaft 24a and the rotating shaft 23a are connected in parallel to the voltage applying unit 28.
- the conductor which is a material of the first rotating conductor 23 and the second rotating conductor 24, has corrosion resistance to the solvent used in the first solution 16 and the second solution 17, and has a conductive property.
- a certain metal material is used.
- DCM is used as a solvent component of the first solution 16 and the second solution 17, and therefore, from the viewpoint of both corrosion resistance and conductivity to DCM, stainless steel is used as the conductor. I have.
- the conductor is not limited to stainless steel, and for example, Hastelloy (registered trademark), a titanium alloy, iron or steel, and copper of Haynes, USA can be preferably used.
- the Hastelloy (registered trademark) is a nickel-based alloy (an alloy obtained by adding molybdenum and / or chromium to nickel).
- one second container 22 is provided with three second rotating conductors 24, which are arranged side by side in the moving direction of the charging belt 13.
- three second containers 22 may be provided in a state where three second containers 22 are arranged in the moving direction of the charging belt 13, and the second rotating conductor 24 may be provided in each second container 22.
- the number of second rotating conductors 24 provided in one second container 22 is not particularly limited. Further, the number of the second rotating conductors 24 is not limited to three in the present example, but may be one, two, or four or more.
- the rotating shafts 23a and 24a and the disk 24b may be electrically connected. Therefore, it is not necessary that the entirety of the rotating shafts 23a, 24a and the disk 24b be formed of a conductor.
- the nonwoven fabric manufacturing facility 10 further includes a collection unit 32 and the above-described voltage application unit 28.
- the collection unit 32 includes the above-described charging belt 13, a moving mechanism 33, a winding unit 34, and a roller 35.
- the charging belt 13 is formed by annularly forming a metal band.
- the charging belt 13 is formed of a material that is charged by applying a voltage by the voltage applying unit 28, and is made of, for example, stainless steel.
- the moving mechanism 33 includes a pair of rollers 37 and 38, a motor 41, and the like.
- the charging belt 13 is horizontally stretched between a pair of rollers 37 and 38.
- a motor 41 disposed outside the spinning chamber 42 is connected to each shaft of one of the rollers 37 and 38, and rotates the rollers 37 and 38 at a predetermined speed. Due to this rotation, the charging belt 13 moves in the longitudinal direction and circulates between the rollers 37 and 38.
- the moving speed of the charging belt 13 is set to 10 cm / hour, but is not limited thereto. Note that only one of the pair of rollers 37 and 38 may be rotated by the motor 41.
- the voltage application unit 28 is an example of a potential difference generator that causes a potential difference between the first rotating conductor 23 and the second rotating conductor 24 and the charging belt 13.
- the voltage applying unit 28 is connected to the first rotating conductor 23 and the second rotating conductor 24, and the charging belt 13, and applies a voltage to these. Thereby, the first rotating conductor 23 and the second rotating conductor 24 are charged to the first polarity, and the charging belt 13 is charged to the second polarity opposite to the first polarity.
- the first solution 16 is charged to the first polarity by coming into contact with the charged disk 23 b of the first rotating conductor 23.
- the first solution 16 attached to the rotating disk 23b is attracted to the charging belt 13 charged to the second polarity at a position above the liquid surface of the first solution 16, It flies like a string toward the charging belt 13.
- the second solution 17 is charged to the first polarity similarly to the first solution 16 by contacting the charged circular plate 24b of the second rotating conductor 24, and the second solution 17 is charged in the charged state. It flies in a thread form from the disk 24b on the liquid surface to the charging belt 13.
- the nanofiber 12 can be formed stably for a long time.
- the nozzle is not blocked by the solidified polymer as in the nozzle method.
- the first rotating conductor 23 and the second rotating conductor 24 are repeatedly immersed in the first solution 16 and the second solution 17 contained in the first container 21 and the second container 22, respectively. Solidification is suppressed, and even if it is solidified in a small amount, it dissolves. Since the nanofibers 12 can be formed stably for a long time, the nonwoven fabric 11 can be formed to be longer and the nonwoven fabric 11 having a larger thickness can be manufactured.
- the first fiber 12a formed from the first solution 16 located on the upstream side of the second solution 17 in the moving direction of the charging belt 13 is collected and deposited on the moving charging belt 13.
- the first layer 11a is formed (first layer forming step).
- the second fiber 12b formed from the second solution 17 is collected and deposited on the first layer 11a, and the second layer 11b is formed so as to overlap the first layer 11a (second layer).
- Layer forming step) thus, the first fiber 12a and the second fiber 12b are collected as the nonwoven fabric 11.
- one of the pair of rollers 37 and 38 has a roller 37 on one side on the left side of the drawing and a roller 38 on the right side. Is formed.
- the second layer 11b is a layer having a desired function as the nonwoven fabric 11. Therefore, the diameter of the second fiber 12b constituting the second layer 11b is set according to the intended function. For example, when the nonwoven fabric 11 has a larger porosity according to a desired function, for example, the second fibers 12b constituting the second layer 11b are formed thinner. However, as the nanofibers 12 in contact with the charging belt 13 are thinner, the adhesive force between the nonwoven fabric and the charging belt becomes stronger, and therefore, when the nonwoven fabric is peeled off as described later, the nonwoven fabric is broken or the peeling residue on the charging belt 13 Likely to happen.
- the first solution 16 has a higher polymer concentration than the second solution 17, so that the first fiber 12a is formed thicker than the second fiber 12b. .
- the nonwoven fabric 11 since the first layer 11a is formed in contact with the charging belt 13 by the first fiber 12a, the nonwoven fabric 11 with reduced adhesive strength to the charging belt 13 is obtained. Therefore, when the nonwoven fabric 11 is peeled off, the nonwoven fabric 11 can be peeled off with a weaker force, the breakage of the nonwoven fabric 11 is suppressed, and the unpeeled residue on the charging belt 13 is also suppressed.
- the first solution 16 is adjusted to a higher concentration than the second solution 17 in advance without adjusting the distance L1 described later, thereby improving the peeling property.
- the second layer 11b is a so-called nonwoven fabric main body having a desired function as the nonwoven fabric 11 as described above. Is a thickness that occupies most of the nonwoven fabric 11. From the viewpoint of improving the peeling property, it is certain that the first layer 11a has a thickness of at least 0.02 mm, that is, a thickness of 0.02 mm or more. It is within the range of 2 mm or less.
- the first layer 11a can also have the intended function as the nonwoven fabric 11.
- the thickness of the first layer 11a may be the same as or larger than the second layer 11b.
- the difference in the concentration of the polymer between the first solution 16 and the second solution 17 is at least 1%, the above-described improvement in the peeling property is more reliable. Since the solvent of the first solution 16 and the solvent of the second solution 17 contain a common component, even if the conditions for forming the first fiber 12a and the second fiber 12b are the same, the The first fiber 12a and the second fiber 12b can be easily formed to have different diameters. Further, in this example, since the same formulation, that is, a mixture in which the components and the mixing ratio of each component are equal are used as the solvent of the first solution 16 and the second solution 17, the effect is more remarkable.
- the first rotating conductor 23 and the second rotating conductor 24 are connected in parallel to the voltage applying unit 28.
- the potentials of the disc 23b and the disc 24b become equal, so that the potentials of the first solution 16 and the second solution 17 also become equal, and thus the potential difference between the charging belt 13 and the first solution 16 becomes equal.
- the difference in polymer concentration between the first solution 16 and the second solution 17 more reliably acts as a difference in the diameter of the fiber 12.
- the roller 35 is provided between the charging belt 13 and the winding unit 34 and supports the nonwoven fabric 11 toward the winding unit 34. Thereby, the nonwoven fabric 11 is stably peeled off from the charging belt 13 at a predetermined position (peeling step).
- the spinning chamber 42 accommodates, for example, the first container 21, the second container 22, and a part of the collection unit 32.
- the spinning chamber 42 is configured to be sealable, thereby preventing the solvent gas and the like from leaking to the outside.
- the solvent gas is obtained by evaporating the solvent of the first solution 16 and the second solution 17.
- the winding unit 34 has a winding shaft 45.
- the take-up shaft 45 is rotated by a motor (not shown), whereby the nonwoven fabric 11 is taken up by a take-up core 46 set on the take-up shaft 45.
- the long nonwoven fabric 11 obtained by being continuously manufactured is cut into a size and a shape according to the use, and provided for use.
- the voltage applied by the voltage application unit 28 be in the range of 5 kV to 100 kV.
- the voltage is 5 kV or more
- the first solution 16 and the second solution 17 are more easily attracted to the charging belt 13 than when the voltage is lower than 5 kV.
- the voltage is equal to or less than 100 kV
- the first solution 16 and the second solution 17 in the spinning space between the first rotating conductor 23 and the second rotating conductor 24 and the charging belt 13 are different from the case where the voltage is higher than 100 kV. Is more reliably suppressed from forming droplets. Therefore, mixing of beads (microspheres) into the nonwoven fabric is prevented.
- the voltage applied by the voltage applying unit 28 is more preferably in the range of 10 kV or more and 80 kV or less, further preferably in the range of 20 kV or more and 60 kV or less, and particularly preferably in the range of 30 kV or more and 50 kV or less. preferable.
- the first rotating conductor 23 and the second rotating conductor 24 are charged to plus (+) and the potential is set to zero by grounding the charging belt 13.
- the second rotating conductor 24 may be negatively ( ⁇ ) charged with a polarity opposite to that of the second rotating conductor 24.
- the first rotating conductor 23 and the second rotating conductor 24 may be negatively charged, and the charging belt 13 may be negatively charged.
- an ion wind supply device for blowing an ion wind on the surface of the charging belt 13 from the roller 37 to the roller 38 opposite to the surface on which the nonwoven fabric 11 is formed may be provided as a potential difference generator.
- the ion wind supply device may be used instead of the voltage application unit 28, or may be used together with the voltage application unit 28. Thereby, the charging belt 13 can be charged to the second polarity or the potential can be adjusted.
- the first rotating conductor 23 and the second rotating conductor 24 have a distance L1 (see FIG. 2) from the charging belt 13 equal to each other, and this is the same in the present embodiment.
- the distance L1 is the distance between the disks 23b and 24b and the charging belt 13 in this example.
- the distance L ⁇ b> 1 is shown only by the first rotating conductor 23, but the same applies to the second rotating conductor 24. Since the distance L1 between the first rotating conductor 23 and the second rotating conductor 24 is equal to each other, the potential difference from the charging belt 13 is also equal to each other. As a result, the difference in polymer concentration between the first solution 16 and the second solution 17 more reliably acts as a difference in the diameter of the fiber 12.
- the distance L1 has an appropriate value depending on the type of the polymer as the fiber material and the solvent 26, the concentration of the polymer in the first solution 16 and the concentration of the polymer in the second solution 17, and the like. Is preferable, and in this embodiment, it is 150 mm.
- the first rotating conductor 23 is configured such that a part of the disc 23 b from which the first solution 16 flies is moved from the liquid surface of the first solution 16 contained in the first container 21. What is necessary is just to be arranged in the state where it came out. Thus, the first solution 16 is continuously applied to the rotating disk 23b, and the potential difference from the charging belt 13 is reliably maintained, so that continuous flight is further ensured. The same applies to the second rotating conductor 24.
- the diameter of the disk 23b is D1
- the distance from the liquid surface of the first solution 16 to the uppermost position of the disk 23b is D2
- the distance from the liquid surface to the lowermost position of the disk 23b is D3.
- the ratio D3 / D1 obtained by dividing the distance D3 by the diameter D1 is preferably in the range of 0.001 or more and less than 1.
- the ratio D3 / D1 is 0.001 or more
- the first solution 16 sufficient to form the first fiber 12a is supplied to the disk 23b as compared with the case where the ratio D3 / D1 is less than 0.001.
- the ratio D3 / D1 is less than 1
- the formation amount of the nanofibers 12 per unit time is larger than in the case where the ratio D3 / D1 is 1 or more, and the potential difference with the charging belt 13 is reliably maintained.
- the ratio D3 / D1 is more preferably in the range of 0.01 or more and 0.8 or less, further preferably in the range of 0.1 or more and 0.7 or less, and 0.3 or more and 0.6 or less. It is particularly preferable that the ratio is within the range. The same applies to the second rotating conductor 24.
- the distance D4 from the rotation center CR to the periphery is constant. Therefore, since the distance between the rotating disk 23b and the charging belt 13 is kept constant, the first fibers 12a are formed stably and continuously. The same applies to the disk 24b.
- the first rotating conductor 23 and the second rotating conductor 24 have the same configuration as the first rotating conductor 23. Therefore, in FIG. 3, the first rotating conductor 23 is illustrated, the first rotating conductor 23 will be described with reference to FIG. 3, and the description of the second rotating conductor 24 will be omitted. As shown in FIG. 3, it is more preferable that the first rotating conductor 23 has a configuration in which a plurality of disks 23 b are provided on the rotating shaft 23 a from the viewpoint of manufacturing the nonwoven fabric 11 to have a larger width.
- the first rotating conductor 23 is arranged in a state where the longitudinal direction of the rotating shaft 23a matches the width direction of the charging belt 13. However, the first rotating conductor 23 may be arranged in a state where the longitudinal direction of the rotating shaft 23a intersects (but does not cross) the width direction of the charging belt 13.
- the number of the disks 23b provided on the rotating shaft 23a is illustrated as five for convenience, but the number of the disks 23b is 15 in this example, and is not particularly limited.
- the pitch P1 between the disks 23b is preferably determined according to the set value of the potential difference between the charging belt 13 and the first rotating conductor 23, and is preferably, for example, in the range of 2 mm or more and 50 mm or less.
- the thickness of the discs 23b is set so that the discs 23b do not come into contact with each other, and may be, for example, 1 mm or a thickness less than 1 mm. In this example, the thickness is 1 mm.
- the pitch P1 is 2 mm or more, the first fibers 12a fly more reliably from the individual disks 23b.
- the pitch P1 is 50 mm or less, the thickness unevenness of the first layer 11a can be more reliably suppressed.
- the pitch P1 is the distance between the centers of the adjacent disks 23 in the thickness direction.
- the rotation shaft 23a and each of the plurality of rotation shafts 24a are preferably parallel to each other, and this is the case in the present example. If the angle between them is within 5 °, it is regarded as parallel. Further, in this example, the first rotating conductor 23 and the plurality of second rotating conductors 24 are arranged in such a manner that the disc 23b and the disc 24b are arranged in a straight line in the moving direction of the charging belt 13, but The disks 23b and the disks 24b of the respective second rotating conductors 24 do not have to be linearly arranged in the moving direction of the charging belt 13.
- the pitches P2 of the rotating shafts 23a and 24a adjacent to each other in the moving direction of the charging belt 13 may be the same or different.
- the pitch P2 between the plurality of rotating shafts 24a provided in one second container 22 is set such that the disks 24b do not abut each other.
- the pitch P2 is a distance between the centers of the adjacent rotation shafts 23a and 24a in the moving direction of the charging belt 13.
- the distance D5 between the rotating shafts 23a and 24a adjacent to each other in the moving direction of the charging belt 13 is preferably determined according to the set value of the potential difference between the charging belt 13 and the first rotating conductor 23 and the second rotating conductor 24. It is preferable that it is in the range of 10 mm or more and 200 mm or less. When the distance D5 is 10 mm or more, the first fibers 12a fly more reliably from the individual disks 23b, and the second fibers 12b fly more reliably from the individual disks 24b. When the distance D5 is 200 mm or less, the formation amount of the nanofibers 12 per unit time is larger, and the productivity of the nonwoven fabric 11 is good.
- the first rotating conductor 23 and the second rotating conductor 24 are not limited to the above example.
- a rotating plate 61 shown in FIG. 5 may be used instead of the disks 23b and 24b.
- the rotating plate 61 includes a plurality of protrusions 61a on the periphery.
- the rotating plate 61 of FIG. 5 includes ten protrusions 61a, the number of the protrusions 61a is not limited to ten, and may be at least two.
- the projection 61a has an inverted V-shape.
- the rotary shaft 61 has the rotary shaft 23a and the rotary shaft 24a inserted through the central opening 61b, and forms a first rotary conductor and a second rotary conductor in a state where the rotary shaft is fixed to the rotary shafts 23a and 24a.
- the apex 61t of the projection 61a becomes a flying source of the first solution 16 and the second solution 17, and flies from the apex 61t. .
- the applied voltage can be suppressed lower than in the case where the discs 23b24b are used, and there is an energy saving effect.
- similar nanofibers 12 can be formed at about 20 kV when the rotating plate 61 is used, as compared with the case where the applied voltage is about 40 kV when the disks 23 b and 24 b are used. .
- the rotating plate 61 has an advantage that the range in which the applied voltage can be set is wider than that of the circular plates 23b and 24b, and therefore, the degree of freedom of the diameter of the nanofibers 12 that can be formed is larger than that of the circular plates 23b and 24b. .
- the plurality of protrusions 61a have the same distance D6 from the rotation center CR to the vertex 61t when the rotating plate 61 is fixed to the rotating shafts 23a and 24a.
- the potential difference between each apex 61t and the charging belt 13 in the case of rotation becomes equal, and as a result, the polymer concentration difference between the first solution 16 and the second solution 17 more reliably reduces the diameter of the fiber 12.
- the distance D6 may be regarded as the same as long as the difference is within 1 mm.
- the maximum diameter is the diameter D1 described above.
- Example 1 to [Example 5] A long nonwoven fabric 11 was manufactured using the nonwoven fabric manufacturing equipment 10, and Examples 1 to 5 were produced. However, instead of the first rotating conductor 23 and the second rotating conductor 24, a first rotating conductor and a second rotating conductor having the rotating plate 61 provided on the rotating shaft 23a and the rotating shaft 24a, respectively, were used.
- the polymer of the first solution 16 and the second solution 17 is TAC.
- the “mixing ratio” column in Table 1 shows the mixing ratio of the first component and the second component of the solvent in terms of the first component and the second component.
- the “concentration” column in Table 1 is a value (unit:%) obtained by ⁇ M1 / (M1 + M2) ⁇ ⁇ 100, where M1 is the mass of the polymer and M2 is the mass of the solvent.
- the “density difference” column is a value (unit:%) obtained by subtracting the concentration (unit:%) of the second solution from the concentration (unit:%) of the first solution.
- the applied voltage was 40 kV
- the distance L1 was 150 mm
- the moving speed of the charging belt 13 was 0.1 m / min.
- the nonwoven fabric 11 was peeled off from the charging belt 13, and the presence or absence and the degree of peeling on the charging belt were evaluated.
- the peeled sample was weighed, and its weight was W1.
- the area of the charging belt 13 from which the sample was peeled off was rubbed, and the nonwoven fabric pieces and fibers remaining in that area were collected as remaining peeling. The remaining amount was weighed, and the weight was W2.
- a nonwoven fabric was manufactured using only the second solution 17 without using the first solution 16 and the first rotating conductor 23.
- the applied voltage, the distance L1, and the moving speed of the charging belt 13 were the same as in the example.
- Nonwoven fabric manufacturing equipment 11 Nonwoven fabric 11a 1st layer 11b 2nd layer 12 Nanofiber 12a 1st fiber 12b 2nd fiber 13 Charging belt 16,17 1st solution, 2nd solution 21,22 1st container, 1st layer 2 containers 23, 24 1st rotating conductor, 2nd rotating conductor 23a, 24a Rotating shaft 23b, 24b Disk 27 Rotating mechanism 28 Voltage application unit 32 Collection unit 33 Moving mechanism 34 Winding unit 35 Roller 37, 38 Roller 41 Motor 42 Spinning chamber 45 Winding shaft 46 Winding core 61 Rotating plate 61a Projection 23o, 24o, 61b Opening 61t Vertex CR Center of rotation L1, D2, D3, D4, D5, D6 Distance D1 Diameter P1, P2 Pitch
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
Abstract
Description
不織布製造設備10を用いて長尺の不織布11を製造し、実施例1~5とした。ただし、第1回転導体23と第2回転導体24との代わりに、回転板61を回転軸23aと回転軸24aとのそれぞれに設けた第1回転導体と第2回転導体を用いた。
A;剥げ残りが0%であった
B;剥げ残りが0%より大きく25%未満であった。
C;剥げ残りが25%以上50%未満であった。
D;剥げ残りが50%以上であった。
11 不織布
11a 第1層
11b 第2層
12 ナノファイバ
12a 第1のファイバ
12b 第2のファイバ
13 帯電ベルト
16,17 第1の溶液,第2の溶液
21,22 第1容器,第2容器
23,24 第1回転導体,第2回転導体
23a,24a 回転軸
23b,24b 円板
27 回転機構
28 電圧印加部
32 捕集部
33 移動機構
34 巻取部
35 ローラ
37,38 ローラ
41 モータ
42 紡糸室
45 巻取軸
46 巻芯
61 回転板
61a 突起
23o,24o,61b 開口
61t 頂点
CR 回転中心
L1,D2,D3,D4,D5,D6 距離
D1 径
P1,P2 ピッチ
Claims (9)
- ポリマーと溶媒とを含有する帯電させた溶液を、前記溶液と逆極性に帯電させたまたは電位をゼロにした長尺のコレクタに誘引することにより、前記ポリマーで形成されたファイバを不織布として捕集する不織布製造方法において、
長尺の前記コレクタを長手方向に移動させ、
前記コレクタの下に配された第1の前記溶液に接しながら回転し、導体で形成された第1回転導体により、前記第1の溶液を帯電することにより、移動中の前記コレクタに第1の前記ファイバで構成された第1層を形成する第1層形成工程と、
前記コレクタの移動方向における前記第1の溶液よりも下流で前記コレクタの下に配された第2の前記溶液に接しながら回転し、導体で形成された第2回転導体により、前記第2の溶液を帯電することにより、第2の前記ファイバで構成された第2層を前記第1層に重ねた状態に形成する第2層形成工程と、
前記第1層と前記第2層とを備える前記不織布を前記コレクタから剥がす剥ぎ取り工程と
を有し、
前記第1の溶液は前記第2の溶液よりも前記ポリマーの濃度が高い不織布製造方法。 - 前記第1の溶液と前記第2の溶液との前記濃度の差は少なくとも1%である請求項1に記載の不織布製造方法。
- 前記第1回転導体と前記第2回転導体とは、前記コレクタからの距離が同じである請求項1または2に記載の不織布製造方法。
- 前記第1回転導体と前記第2回転導体とは、前記コレクタとの電位差が同じである請求項1ないし3のいずれか1項に記載の不織布製造方法。
- 前記第1回転導体は、回転中心から周縁までの距離が一定である請求項1ないし4のいずれか1項に記載の不織布製造方法。
- 前記第1回転導体は、周縁に複数の突起を備え、前記複数の突起の頂点は回転中心からの距離が同じである請求項1ないし4のいずれか1項に記載の不織布製造方法。
- 前記ポリマーは、セルローストリアセテートと、セルロースジアセテートと、セルロースプロピオネートと、セルロースブチレートと、セルロースアセテートプロピオネートと、ニトロセルロースと、エチルセルロースと、カルボキシメチルエチルセルロースとの少なくともいずれかである請求項1ないし6のいずれか1項に記載の不織布製造方法。
- 前記溶媒は、ジクロロメタン、クロロホルム、酢酸メチル、アセトンの少なくともいずれかを含有する請求項1ないし7のいずれか1項に記載の不織布製造方法。
- ポリマーと溶媒とを含有する帯電させた溶液を、前記溶液と逆極性に帯電させたまたは電位をゼロにしたコレクタに誘引することにより、前記ポリマーで形成されたファイバを不織布として捕集する不織布製造設備において、
長尺の前記コレクタと、
前記コレクタを長手方向に移動させる移動機構と、
第1の前記溶液が収容され、前記コレクタの下に配される第1容器と、
前記第1の溶液に接しながら回転し、導体で形成された第1回転導体と、
第2の前記溶液が収容され、前記コレクタの移動方向における前記第1容器よりも下流、かつ、前記コレクタの下に配される第2容器と、
前記第2容器内の前記第2の溶液に接しながら回転し、導体で形成された第2回転導体と、
前記第1回転導体及び前記第2回転導体と、前記コレクタとに電位差を生じさせる電位差発生器と、
を備え、
前記第1の溶液は前記第2の溶液よりも前記ポリマーの濃度が高い不織布製造設備。
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