JP2020090764A - Fibrous body molding method and fibrous body molding apparatus - Google Patents

Abstract

To provide a fiber assembly forming method which enables a liquid containing resin particles to permeate into the internal part of a web.SOLUTION: A fiber assembly forming method comprises a step of applying a liquid to a web containing a plurality of fibers, the liquid containing resin particles for binding the fibers. The liquid has a surface tension of 50 mN/m or less at 20°C.SELECTED DRAWING: Figure 2

Description

The present invention relates to a fiber body molding method and a fiber body molding apparatus.

For downsizing and energy saving, a dry method for forming a fibrous body that does not use water as much as possible has been proposed. For example, in Patent Document 1, used paper pulp fibers and thermoplastic resin fibers are dry-mixed to form a web, and the puncture of the thermoplastic resin is melted by heating, so that the used paper pulp fibers and the thermoplastic resin Bonding with fibers is described.

JP, 10-86247, A

When binding a plurality of fibers using a binder such as a thermoplastic resin as described above, it is desirable that the binder penetrates into the inside of the web. If the binder does not penetrate into the inside of the web, paper powder is likely to be generated, and for example, when printing a sheet with an inkjet printer, the paper powder may block the nozzle holes of the inkjet printer.

One aspect of the fibrous body molding method according to the present invention is
A step of applying a liquid containing resin particles for binding the plurality of fibers to a web containing a plurality of fibers,
The surface tension of the liquid is 50 mN/m or less at 20°C.

In one aspect of the fibrous body molding method,
The average particle size of the resin particles may be 10 nm or more and 5 μm or less.

In one aspect of the fibrous body molding method,
The resin particles may be a thermoplastic resin or a thermosetting resin.

In one aspect of the fibrous body molding method,
The liquid may include a penetrant.

In one aspect of the fibrous body molding method,
The liquid may include a moisturizer.

In one aspect of the fibrous body molding method,
In the step of applying the liquid,
The liquid may be applied to the web having a bulk density of 0.09 g/cm ³ or more.

In one aspect of the fibrous body molding method,
In the step of applying the liquid,
The liquid may be applied to the web having a bulk density of 0.80 g/cm ³ or less.

In one aspect of the fibrous body molding method,
The method may include the step of pressurizing the web coated with the liquid.

In one aspect of the fibrous body molding method,
The method may include heating the web coated with the liquid.

In one aspect of the fibrous body molding method,
In the step of applying the liquid,
The liquid may be applied by an inkjet method.

One aspect of the fibrous body molding apparatus according to the present invention,
A web containing a plurality of fibers, including a liquid application device for applying a liquid containing resin particles for binding the plurality of fibers,
The surface tension of the liquid is 50 mN/m or less at 20°C.

The figure which shows typically the fibrous body shaping|molding apparatus which concerns on 1st Embodiment. The figure which shows typically the fibrous body shaping|molding apparatus which concerns on 1st Embodiment. The figure which shows typically the fiber body shaping|molding method which concerns on 1st Embodiment. The figure which shows typically the fibrous body shaping|molding apparatus which concerns on the 1st modification of 1st Embodiment. The figure which shows typically the fibrous body shaping|molding apparatus which concerns on the 2nd modification of 1st Embodiment. The figure which shows typically the fiber body shaping|molding apparatus which concerns on the 3rd modification of 1st Embodiment. The figure which shows typically the fiber body shaping|molding apparatus which concerns on the 3rd modification of 1st Embodiment. The figure which shows typically the fibrous body shaping|molding apparatus which concerns on 2nd Embodiment. The figure which shows typically the fiber body shaping|molding method which concerns on 2nd Embodiment. The figure which shows typically the fibrous body shaping|molding apparatus which concerns on the modification of 2nd Embodiment. The table which shows the composition of liquid L1-L5. 9 is a table showing evaluation results of continuous printability and liquid stability of Examples 1 to 14 and Comparative Example 1.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings. The embodiments described below do not unduly limit the contents of the invention described in the claims. In addition, not all of the configurations described below are essential configuration requirements of the invention.

1. 1. First Embodiment 1.1. Fibrous body forming apparatus 1.1.1. Configuration First, the fibrous body molding apparatus according to the first embodiment will be described with reference to the drawings. FIG. 1 is a diagram schematically showing a fibrous body molding device 100 according to the first embodiment.

The fibrous body forming apparatus 100 is an apparatus suitable for producing new paper, for example, by dry disintegrating used waste paper as a raw material to form fibers, and then pressing, heating, and cutting the waste paper. .. The fibrous body forming apparatus 100 manufactures various thicknesses and sizes of paper such as A4 or A3 office paper and business card paper by controlling the density, thickness, and shape of paper to suit the application. can do.

The fibrous body molding device 100 includes, for example, a supply unit 10, a crushing unit 12, a defibrating unit 20, a sorting unit 40, a first web forming unit 45, a rotating body 49, a stacking unit 60, and a first unit. The 2 web formation part 70, the conveyance part 79, the sheet formation part 80, and the cutting part 90 are included.

Further, the fibrous body forming apparatus 100 includes humidifying units 202, 204, 206, 208, 210, 212 for the purpose of humidifying the raw material and humidifying the space in which the raw material moves.

The humidifiers 202, 204, 206, and 208 are configured by, for example, vaporizers or warm air vaporizers. That is, the humidifying units 202, 204, 206, 208 have filters (not shown) that infiltrate water, and supply humidified air with increased humidity by passing air through the filters. The humidifying units 202, 204, 206, 208 may include a heater (not shown) that effectively increases the humidity of the humidified air.

The humidifiers 210 and 212 are, for example, ultrasonic wave humidifiers. That is, the humidification sections 210 and 212 have a vibration section (not shown) for atomizing water, and supply mist generated by the vibration section.

The supply unit 10 supplies the raw material to the crushing unit 12. The raw material supplied to the crushing section 12 may be any material containing fibers, and examples thereof include paper, pulp, pulp sheet, non-woven fabric, cloth, and woven fabric. Below, the structure which the fibrous body shaping|molding apparatus 100 makes waste paper a raw material is illustrated. The supply unit 10 includes, for example, a stacker that stacks and accumulates used paper, and an automatic feeding device that sends the used paper from the stacker to the crushing unit 12. Further, it is not always necessary to align and stack the waste paper, and waste paper of various sizes or waste paper of various shapes may be supplied to the stacker in pieces.

The coarse crushing unit 12 cuts the raw material supplied by the supply unit 10 with a coarse crushing blade 14 to form coarse crushed pieces. The coarse crushing blade 14 cuts the raw material in the air such as the air. The coarse crushing unit 12 has, for example, a pair of coarse crushing blades 14 that cut the raw material between them, and a drive unit that rotates the coarse crushing blade 14, and can have the same configuration as a so-called shredder. The shape and size of the coarsely crushed pieces are arbitrary and may be suitable for the defibration process in the defibration unit 20. The crushing unit 12 cuts the raw material into pieces of paper having a size of, for example, 1 cm to several cm square or smaller.

The coarse crushing unit 12 has a chute 9 that receives the coarse crushed pieces that are cut by the coarse crushing blade 14 and fall. The chute 9 has, for example, a tapered shape in which the width gradually narrows in the direction in which the coarsely crushed pieces flow. Therefore, the chute 9 can receive many coarsely crushed pieces. The chute 9 is connected to the pipe 2 communicating with the defibrating unit 20, and the pipe 2 forms a transport path for transporting the coarsely crushed pieces to the defibrating unit 20. The coarse fragments are collected by the chute 9 and conveyed to the defibrating unit 20 through the tube 2. The coarsely crushed pieces are conveyed in the tube 2 toward the defibrating unit 20 by, for example, an air flow generated by a blower (not shown).

Humidified air is supplied by the humidifying unit 202 to the chute 9 included in the crushing unit 12 or the vicinity of the chute 9. As a result, it is possible to suppress the phenomenon that the roughly crushed material cut by the roughly crushing blade 14 is attracted to the chute 9 or the inner surface of the tube 2 due to static electricity. Further, since the coarsely crushed material cut by the coarsely crushing blade 14 is conveyed to the defibrating unit 20 together with humidified high-humidity air, an effect of suppressing adhesion of defibrated substances inside the defibrating unit 20 can be expected. .. Further, the humidifying unit 202 may be configured to supply humidified air to the coarsely crushing blade 14 to remove the charge of the raw material supplied by the supply unit 10. Further, the humidification unit 202 may be used together with an ionizer to remove the charge.

The defibrating unit 20 defibrates the crushed material cut by the crushing unit 12. More specifically, the defibrating unit 20 defibrates the raw material cut by the crushing unit 12 to generate a defibrated material. Here, “to disintegrate” means to loosen and unravel the raw material formed by binding a plurality of fibers into individual fibers. The defibrating unit 20 has a function of separating substances such as resin particles, ink, toner, and anti-bleeding agent attached to the raw material from the fibers.

What passed through the defibrating unit 20 is called a defibrated material. The defibrated material includes, in addition to the disentangled defibrated fibers, resin particles separated from the fibers when unraveling the fibers, that is, resin particles for binding a plurality of fibers, ink, toner, etc. It may also contain coloring materials and additives such as anti-bleeding agents and paper strengthening agents. The shape of the unraveled defibrated material is a string or a flat string. The disentangled defibrated material may exist in a state in which it is not entangled with other defibrated fibers, that is, in an independent state, or entangled with other defibrated defibrated material to form a lump. It may exist in a state, that is, in a state of forming a lump.

The defibrating unit 20 performs defibration by a dry method. Here, the process of performing defibration or the like in air, such as in the air, rather than in a liquid, is called a dry process. The disentanglement part 20 is comprised using the impeller mill, for example. Specifically, the defibrating unit 20 has a rotor that rotates at a high speed and a liner that is located on the outer periphery of the rotor, although not shown. The coarsely crushed pieces cut by the coarsely crushing section 12 are sandwiched between the rotor and the liner of the defibrating section 20 to be defibrated. The defibrating unit 20 generates an airflow by the rotation of the rotor. By this air flow, the defibrating unit 20 can suck the coarsely crushed material, which is a raw material, from the tube 2 and convey the defibrated material to the discharge port 24. The defibrated material is sent out from the outlet 24 to the pipe 3, and is conveyed to the sorting unit 40 via the pipe 3.

As described above, the defibrated material generated in the defibrating unit 20 is conveyed from the defibrating unit 20 to the sorting unit 40 by the airflow generated by the defibrating unit 20. Further, in the illustrated example, the fibrous body forming apparatus 100 includes the defibrating blower 26 that is an airflow generating device, and the defibrated material is conveyed to the sorting unit 40 by the airflow generated by the defibrating blower 26. The defibration blower 26 is attached to the tube 3, sucks air together with the defibrated material from the defibration unit 20, and blows the air to the selection unit 40.

The sorting section 40 is provided with an inlet 42 through which the defibrated material defibrated by the defibrating section 20 from the tube 3 flows in together with the airflow. The sorting unit 40 sorts the defibrated material introduced into the inlet 42 according to the length of the fiber. Specifically, the sorting unit 40 sets a defibrated product having a predetermined size or less among the defibrated products defibrated by the defibrating unit 20 as a first selected product, and a defibrated product larger than the first selected product. Is selected as the second selected product. The first sorted material includes fibers or particles, and the second sorted material is, for example, large fibers, unfibrillated pieces, crushed pieces that have not been sufficiently defibrated, or defibrated fibers are aggregated or entangled. Including lumps, etc.

The selection unit 40 includes, for example, a drum unit 41 and a housing unit 43 that houses the drum unit 41.

The drum portion 41 is a cylindrical sieve that is rotationally driven by a motor. The drum portion 41 has a net and functions as a screen. With this mesh, the drum portion 41 selects a first sorted product having a smaller mesh opening size and a second sorted product having a larger mesh opening size. As the net of the drum portion 41, for example, a wire net, an expanded metal obtained by extending a notched metal plate, or a punching metal in which holes are formed in the metal plate by a press machine or the like can be used.

The defibrated material introduced into the introduction port 42 is sent into the inside of the drum portion 41 together with the airflow, and the rotation of the drum portion 41 causes the first sorted material to drop downward from the mesh of the drum portion 41. The second sorted material that cannot pass through the mesh of the drum portion 41 is caused to flow by the airflow flowing into the drum portion 41 from the inlet 42, is guided to the outlet 44, and is sent out to the pipe 8.

The pipe 8 connects the inside of the drum portion 41 and the pipe 2. The second sorted material flowing through the pipe 8 flows through the pipe 2 together with the coarsely crushed pieces cut by the coarsely crushing unit 12, and is guided to the inlet 22 of the defibrating unit 20. As a result, the second sorted material is returned to the defibrating unit 20 and defibrated.

Further, the first sorted matter sorted by the drum portion 41 passes through the mesh of the drum portion 41 and is dispersed in the air, and is distributed to the mesh belt 46 of the first web forming portion 45 located below the drum portion 41. Descend towards.

The first web forming unit 45 has a mesh belt 46, a roller 47, and a suction unit 48. The mesh belt 46 is an endless belt, is suspended by three rollers 47, and is conveyed in the direction indicated by the arrow in the figure by the movement of the rollers 47. The surface of the mesh belt 46 is composed of a net having openings of a predetermined size. Of the first sorted matter that descends from the sorting unit 40, the fine particles having a size that passes through the mesh drop below the mesh belt 46, and fibers having a size that cannot pass through the mesh are deposited on the mesh belt 46. It is conveyed in the arrow direction together with the mesh belt 46. The fine particles falling from the mesh belt 46 are relatively small or low in the defibrated material, that is, include resin particles, coloring materials, additives, etc., which are not necessary for binding the fibers to each other. The removed product is not used by the body forming apparatus 100 for manufacturing the sheet S.

The mesh belt 46 moves at a constant speed V1 during the normal operation of manufacturing the sheet S. Here, “during normal operation” refers to an operation other than during execution of start control and stop control of the fibrous body molding apparatus 100, and more specifically, the fibrous body molding apparatus 100 manufactures a sheet S of a desired quality. It refers to while.

Therefore, the defibrated material that has been defibrated by the defibrating unit 20 is sorted by the sorting unit 40 into the first sorted material and the second sorted material, and the second sorted material is returned to the defibrated portion 20. Further, the removed material is removed from the first sorted material by the first web forming unit 45. The remainder obtained by removing the removed material from the first sorted material is a material suitable for manufacturing the sheet S, and this material is deposited on the mesh belt 46 to form the first web W1.

The suction unit 48 sucks air from below the mesh belt 46. The suction unit 48 is connected to the dust collecting unit 27 via the pipe 23. The dust collector 27 is a filter-type or cyclone-type dust collector and separates fine particles from the air flow. A collection blower 28 is installed downstream of the dust collection unit 27, and the collection blower 28 functions as a dust collection suction unit that sucks air from the dust collection unit 27. Further, the air discharged by the collection blower 28 is discharged to the outside of the fibrous body molding apparatus 100 via the pipe 29.

In the fibrous body molding apparatus 100, the collection blower 28 sucks air from the suction section 48 through the dust collecting section 27. In the suction unit 48, the fine particles that pass through the mesh of the mesh belt 46 are sucked together with the air and sent to the dust collecting unit 27 through the pipe 23. The dust collecting unit 27 separates and accumulates the fine particles that have passed through the mesh belt 46 from the air flow.

Therefore, the fibers obtained by removing the removed material from the first sorted material are accumulated on the mesh belt 46 to form the first web W1. The collection blower 28 sucks to promote the formation of the first web W1 on the mesh belt 46 and quickly remove the removed matter.

Humidifying air is supplied to the space including the drum portion 41 by the humidifying portion 204. The humidified air humidifies the first sorted material inside the sorting unit 40. As a result, the adhesion of the first sorted matter to the mesh belt 46 due to the electrostatic force can be weakened, and the first sorted matter can be easily separated from the mesh belt 46. Furthermore, it is possible to prevent the first sorted matter from adhering to the inner wall of the rotating body 49 or the housing portion 43 due to the electrostatic force. Further, the suction unit 48 can efficiently suck the removed material.

In addition, in the fibrous body molding apparatus 100, the configuration for selecting and separating the first sorted material and the second sorted material is not limited to the sorting unit 40 including the drum portion 41. For example, the defibrated material that has been defibrated by the defibrating unit 20 may be classified by a classifier. As the classifier, for example, a cyclone classifier, an elbow jet classifier, or an eddy classifier can be used. By using these classifiers, it is possible to sort and separate the first sorted product and the second sorted product. Furthermore, by the above classifier, a relatively small or low density of defibrated material, that is, a removed material containing resin particles, coloring materials, additives, etc., which are unnecessary for binding fibers to each other, It is possible to realize a configuration of separating and removing. For example, the fine particles contained in the first sorted material may be removed from the first sorted material by a classifier. In this case, the second sorted matter may be returned to, for example, the defibrating unit 20, the removed matter may be collected by the dust collecting section 27, and the first sorted matter excluding the removed matter may be sent to the pipe 54. it can.

In the transport path of the mesh belt 46, the humidifying section 210 supplies air including mist to the downstream side of the selecting section 40. The mist, which is fine particles of water generated by the humidifying section 210, descends toward the first web W1 and supplies moisture to the first web W1. As a result, the amount of water contained in the first web W1 is adjusted, and adsorption of fibers to the mesh belt 46 due to static electricity can be suppressed.

The fibrous body forming apparatus 100 includes a rotating body 49 that divides the first web W1 accumulated on the mesh belt 46. The first web W<b>1 is separated from the mesh belt 46 at the position where the mesh belt 46 is folded back by the roller 47 and is divided by the rotating body 49.

The first web W1 is a soft material in which fibers are deposited to have a web shape, and the rotating body 49 loosens the fibers of the first web W1.

The configuration of the rotating body 49 is arbitrary, but in the illustrated example, the rotating body 49 has a rotary vane shape having plate-shaped vanes and rotating. The rotating body 49 is arranged at a position where the first web W<b>1 separated from the mesh belt 46 and the blade come into contact with each other. By the rotation of the rotating body 49, for example, the rotation in the direction indicated by the arrow R in the figure, the blade collides with the first web W1 separated from the mesh belt 46 and conveyed, and is divided, and the subdivided body P is generated.

The rotating body 49 is preferably installed at a position where the blades of the rotating body 49 do not collide with the mesh belt 46. For example, the distance between the tips of the blades of the rotating body 49 and the mesh belt 46 can be set to 0.05 mm or more and 0.5 mm or less. In this case, the rotating body 49 prevents the mesh belt 46 from being damaged without damaging the mesh belt 46. The 1 web W1 can be efficiently divided.

The subdivided body P divided by the rotating body 49 descends inside the pipe 7 and is conveyed to the pipe 54 by the airflow flowing inside the pipe 7.

In addition, humidified air is supplied to the space including the rotating body 49 by the humidifying unit 206. As a result, it is possible to suppress the phenomenon that the fibers are attracted to the inside of the tube 7 and the blades of the rotating body 49 due to static electricity.

Due to the air flow generated by the blower 56, the subdivided body P that descends in the pipe 7 is sucked into the pipe 54 and passes through the blower 56. The subdivided body P is conveyed to the deposition unit 60 through the pipe 54 by the action of the air flow generated by the blower 56 and the action of the rotating unit such as the blade of the blower 56.

The deposition unit 60 deposits the defibrated material defibrated by the defibration unit 20. More specifically, the deposition unit 60 introduces the subdivided body P from the introduction port 62, loosens the entangled defibrated material, and disperses the defibrated material in the air. Thereby, the deposition unit 60 can deposit the defibrated material on the second web forming unit 70 with good uniformity.

The deposition unit 60 includes a drum unit 61 and a housing unit 63 that houses the drum unit 61. The drum portion 61 is a cylindrical sieve that is rotationally driven by a motor. The drum portion 61 has a net and functions as a screen. Due to this mesh, the drum portion 61 allows fibers and particles having a smaller mesh opening to pass therethrough, and lowers from the drum portion 61. The configuration of the drum portion 61 is the same as the configuration of the drum portion 41, for example.

The “sieve” of the drum unit 61 does not have to have a function of selecting a specific object. That is, the “sifter” used as the drum part 61 means that it is provided with a net, and the drum part 61 may drop all the defibrated material introduced into the drum part 61.

The second web forming unit 70 is disposed below the drum unit 61. The second web forming unit 70 deposits the passing material that has passed through the depositing unit 60 to form the second web W2. The second web forming unit 70 has, for example, a mesh belt 72, a roller 74, and a suction mechanism 76.

The mesh belt 72 is an endless belt, is suspended by a plurality of rollers 74, and is conveyed in the direction indicated by the arrow in the figure by the movement of the rollers 74. The mesh belt 72 is made of, for example, metal, resin, cloth, or non-woven fabric. The surface of the mesh belt 72 is composed of a net having openings of a predetermined size. Among the fibers descending from the drum portion 61, the fibers of the size that can pass through the mesh drop below the mesh belt 72, and the fibers of the size that cannot pass through the mesh are accumulated on the mesh belt 72, and the mesh belt 72 Along with it, it is conveyed in the direction of the arrow. The mesh belt 72 moves at a constant speed V2 during the normal operation of manufacturing the sheet S. The normal operation is as described above.

The mesh of the mesh belt 72 is fine and can be sized so that most of the fibers falling from the drum portion 61 do not pass through.

The suction mechanism 76 is provided below the mesh belt 72. The suction mechanism 76 includes a suction blower 77, and the suction force of the suction blower 77 can generate an airflow directed downward in the suction mechanism 76.

The suction mechanism 76 sucks the defibrated material dispersed in the air by the deposition unit 60 onto the mesh belt 72. As a result, the formation of the second web W2 on the mesh belt 72 can be promoted, and the discharge speed from the deposition unit 60 can be increased. Furthermore, the suction mechanism 76 can form a downflow in the falling path of the defibrated material, and can prevent the defibrated material from being entangled during the fall.

The suction blower 77 may discharge the air sucked from the suction mechanism 76 to the outside of the fibrous body molding device 100 through a collection filter (not shown). Alternatively, the air sucked by the suction blower 77 may be sent to the dust collecting unit 27, and the removed substances contained in the air sucked by the suction mechanism 76 may be collected.

Humidified air is supplied to the space including the drum portion 61 by the humidifying portion 208. This humidified air can humidify the inside of the deposition unit 60, suppress the adhesion of the fibers to the housing unit 63 due to electrostatic force, and promptly lower the fibers to the mesh belt 72 to form the second web W2 having a preferable shape. Can be formed.

As described above, the second web W2 containing a large amount of air and in a soft and bulged state is formed by passing through the deposition unit 60 and the second web formation unit 70. The second web W2 deposited on the mesh belt 72 is conveyed to the sheet forming unit 80.

In the transport path of the mesh belt 72, the humidifying section 212 supplies air containing mist to the downstream side of the deposition section 60. As a result, the mist generated by the humidifying section 212 is supplied to the second web W2, and the amount of water contained in the second web W2 is adjusted. As a result, it is possible to suppress adsorption of fibers to the mesh belt 72 due to static electricity.

The fibrous body forming apparatus 100 has a conveyance unit 79 that conveys the second web W2 on the mesh belt 72 to the sheet forming unit 80. The transport unit 79 has, for example, a mesh belt 79a, a roller 79b, and a suction mechanism 79c.

The suction mechanism 79c includes a blower (not shown), and generates an upward airflow on the mesh belt 79a by the suction force of the blower. This air flow sucks the second web W2, and the second web W2 is separated from the mesh belt 72 and adsorbed to the mesh belt 79a. The mesh belt 79a moves by the rotation of the roller 79b and conveys the second web W2 to the sheet forming unit 80. The moving speed of the mesh belt 72 and the moving speed of the mesh belt 79a are, for example, the same.

In this way, the transport unit 79 peels the second web W2 formed on the mesh belt 72 from the mesh belt 72 and transports it.

The sheet forming unit 80 forms the sheet S from the deposits deposited by the depositing unit 60. More specifically, the sheet forming unit 80 pressurizes and heats the second web W2 accumulated on the mesh belt 72 and conveyed by the conveying unit 79 to form the sheet S.

The sheet forming unit 80 includes a pressing unit 82 that presses the second web W2, and a heating unit 84 that heats the second web W2 pressed by the pressing unit 82.

The pressurizing unit 82 includes a pair of calender rollers 85, and presses the second web W2 by sandwiching it with a predetermined nip pressure. The thickness of the second web W2 is reduced by being pressed, and the density of the second web W2 is increased. One of the pair of calender rollers 85 is a drive roller driven by a motor (not shown), and the other is a driven roller. The calendar roller 85 is rotated by the driving force of the motor and conveys the second web W<b>2, which has a high density due to the pressure, toward the heating section 84.

The heating unit 84 is composed of, for example, a heating roller, a heat press molding machine, a hot plate, a warm air blower, an infrared heater, a flash fixing device, and the like. In the illustrated example, the heating unit 84 includes a pair of heating rollers 86. The heating roller 86 is heated to a preset temperature by a heater installed inside or outside. The heating roller 86 sandwiches the second web W2 pressed by the calendar roller 85 to apply heat to form the sheet S.

One of the pair of heating rollers 86 is a driving roller driven by a motor (not shown), and the other is a driven roller. The heating roller 86 is rotated by the driving force of the motor to convey the heated sheet S toward the cutting section 90.

In this way, the second web W2 formed in the deposition section 60 is pressed and heated in the sheet forming section 80 to become the sheet S.

The number of calender rollers 85 included in the pressing unit 82 and the number of heating rollers 86 included in the heating unit 84 are not particularly limited.

The cutting unit 90 cuts the sheet S formed by the sheet forming unit 80. In the illustrated example, the cutting unit 90 includes a first cutting unit 92 that cuts the sheet S in a direction intersecting the conveyance direction of the sheet S, and a second cutting unit 94 that cuts the sheet S in a direction parallel to the conveyance direction. ,have. The second cutting unit 94 cuts the sheet S that has passed through the first cutting unit 92, for example.

As described above, the single-cut sheet S having a predetermined size is formed. The cut single-cut sheet S is discharged to the discharge unit 96. The discharge unit 96 has a tray or a stacker on which sheets S of a predetermined size are placed.

Although not shown, the humidifying units 202, 204, 206, 208 may be configured by a single vaporizing humidifier. In this case, the humidified air generated by one humidifier is branched and supplied to the crushing unit 12, the housing unit 43, the pipe 7, and the housing unit 63. This configuration can be easily realized by branching and installing a duct for supplying humidified air. Further, it is also possible to configure the humidifying sections 202, 204, 206, 208 by two or three vaporization type humidifiers.

In addition, the humidifying units 210 and 212 may be configured by one ultrasonic humidifier or may be configured by two ultrasonic humidifiers. For example, air containing mist generated by one humidifier is branched and supplied to the humidifiers 210 and 212.

1.1.2. Liquid Coating Device Next, a liquid coating device of the fibrous body molding device 100 will be described with reference to the drawings. FIG. 2 is a diagram schematically showing the liquid application device 102 of the fibrous body molding device 100. The fibrous body molding apparatus 100 includes a liquid application device 102, as shown in FIG. 2.

Note that, for convenience, the liquid application device 102 is not shown in FIG. 1. Further, although FIG. 1 illustrates an example in which the second web W2 is conveyed obliquely downward from the pressing unit 82, in FIG. 2, the second web W2 is horizontal from the pressing unit 82. The example conveyed in the direction is shown.

The liquid application device 102 applies the liquid L containing the resin particles for binding the plurality of fibers to the second web W2 including the plurality of fibers. Hereinafter, the “second web W2” is also simply referred to as “web W2”.

The liquid application device 102 is an inkjet head, and applies the liquid L by an inkjet method. The liquid coating device 102 may be a line head type inkjet head having a width equal to or larger than the width of the web W2. As a result, productivity can be improved. The liquid coating device 102 may be a system in which the head itself moves instead of the line head system.

For example, two liquid application devices 102 are provided. In the illustrated example, the web W2 is located between the two liquid application devices 102. One of the two liquid application devices 102 applies the liquid L to one surface A1 of the web W2, and the other liquid application device 102 of the two liquid application devices 102 applies the web W2. The liquid L is applied to the other surface A2.

In the illustrated example, the two liquid application devices 102 are provided so as to overlap each other in the thickness direction of the web W2. The two liquid application devices 102 may apply the liquid L to the web W2 at the same time.

The pressurizing unit 82 pressurizes the web W2 on which the liquid L is applied by the liquid applying device 102. Pressure pressing 82 applies to the web W2 is, for example, 30 kgf / cm ² or more 1000 kgf / cm ² or less, preferably 200 kgf / cm ² or more 700 kgf / cm ² or less.

The heating unit 84 heats the web W2 coated with the liquid L by the liquid coating device 102. In the illustrated example, the heating unit 84 presses the web W2 pressed by the pressing unit 82. The web W2 is heated by the heating unit 84 to become the sheet S. The temperature of the heating section 84 is, for example, 70° C. or higher and 220° C. or lower, and preferably 100° C. or higher and 180° C. or lower.

The liquid L contains resin particles that bind the plurality of fibers of the web W2. The liquid L is an emulsion in which resin particles are dispersed. The resin particles are a binder for binding a plurality of fibers. The web W2 before the liquid L is applied does not include, for example, resin particles that bind a plurality of fibers. The resin particles are particles of resin, and the shape thereof is, for example, substantially spherical, preferably spherical.

The resin particles contained in the liquid L are, for example, a thermoplastic resin or a thermosetting resin. As the thermoplastic resin, for example, styrene butadiene copolymer, acrylonitrile butadiene copolymer, acrylic ester copolymer, styrene acrylic acid copolymer, polyurethane, polyester, polyvinyl acetate, ethylene vinyl acetate copolymer, poly Examples include acrylamide, polyvinyl alcohol, and polyvinylpyrrolidone. Examples of the thermosetting resin include epoxy resin, phenol resin, urea resin, melamine resin, unsaturated polyester resin, alkyd resin, diallyl phthalate resin, vinyl ester resin, and thermosetting polyimide. The liquid L may contain these resins individually or may contain a plurality of them.

The glass transition temperature of the thermoplastic resin and the thermosetting resin contained in the liquid L is, for example, −50° C. or higher and 130° C. or lower, and preferably −30° C. or higher and 100° C. or lower. When the glass transition temperature of the resin particles is within this range, the binding of fibers can be improved and the paper strength can be increased.

The content of the resin particles in the liquid L is, for example, 0.1% by mass or more and 30.0% by mass or less, and preferably 0.1% by mass or more and 20.0% by mass or less. When the content is 0.1% by mass or more and 30.0% by mass or less, the viscosity of the liquid L can be reduced to the extent that the liquid L can be sufficiently ejected from the liquid application device 102.

The average particle size of the resin particles is, for example, 5 nm or more and 8 μm or less, preferably 9 nm or more and 6 μm or less, more preferably 10 nm or more and 5 μm or less, and still more preferably 10 nm or more and 300 nm or less. When the average particle diameter is in such a range, the resin particles can be sufficiently dispersed on the fiber surface and the fiber adhesive contact points can be increased, so that the paper strength of the sheet S can be increased.

The “average particle size” is obtained by diluting the liquid L with water, for example, pure water, and measuring the particle size distribution in the diluted state with, for example, a positive particle size distribution meter “Microtrac UPA-150” manufactured by Nikki Co., Ltd. It means a cumulative particle size value of 50% when measured.

The plurality of fibers included in the web W2 are bound by the resin particles included in the liquid L by being heated by the heating unit 84. Although not shown, the web W2 to which the liquid L is attached may be heated separately from the heating unit 84 by hot air, infrared rays, electromagnetic waves, a heat roller, a heat press, or the like. As a result, it is possible to promote the melting and binding of the resin particles contained in the liquid L, the gelatinization, and the drying of water and the like.

The surface tension of the liquid L at 20° C. is 50 mN/m or less, preferably 20 mN/m or more and 50 mN/m or less, and more preferably 45 mN/m or more and 50 mN/m or less. By setting the surface tension of the liquid L to 50 mN/m or less at 20° C., the liquid L can be penetrated into the inside of the web W2 and the generation of paper dust can be suppressed. Further, by setting the surface tension of the liquid L to 20 mN/m or more at 20° C., the ink repellency of the nozzle plate of the inkjet head can be suppressed from being lowered, and ejection failure can be prevented. The surface tension can be measured with a surface tensiometer.

The viscosity of the liquid L at 20° C. is preferably 8.0 mPa·s or less. When the viscosity of the liquid L exceeds 8.0 mPa·s, the viscosity may be too large, and it may be difficult to eject the liquid L from the liquid coating device 102.

The liquid L may contain a penetrant. Thereby, the permeability of the liquid L in the thickness direction of the web W2 can be improved. Therefore, the fiber binding inside the sheet S can be improved, the delamination of the sheet S can be reduced, and the tensile strength can be increased. As the penetrant contained in the liquid L, for example, glycol ethers such as triethylene glycol monobutyl ether, reethylene glycol dimethyl ether, triethylene glycol diethyl ether, triethylene glycol dibutyl ether, triethylene glycol methyl butyl ether, and silicone surfactants. , Acetylene glycol-based surfactants, acetylene alcohol-based surfactants, fluorine-based surfactants and the like. The liquid L may contain these penetrants alone or may contain a plurality of them.

The content of the penetrant in the liquid L is, for example, 0.1% by mass or more and 30.0% by mass or less, preferably 0.1% by mass or more and 20.0% by mass or less, and more preferably 1.0% by mass or more. The amount is not less than mass% and not more than 10.0 mass %. When the content is 0.1% by mass or more and 30.0% by mass or less, the penetration of the liquid L into the web W2 can be promoted, and the paper strength of the sheet S can be increased.

The liquid L may contain a moisturizer. As a result, when the liquid L is ejected, it is possible to make it difficult for the nozzle holes of the liquid application device 102 to be clogged. As the moisturizing agent contained in the liquid L, for example, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, 1,3-propanediol, 1,3-butylene glycol, 1,4-butanediol, 1,5- Pentanediol, 1,6-hexanediol, 2-ethyl-2-methyl-1,3-propanediol, 2-methyl-2-propyl-1,3-propanediol, 2-methyl-1,3-propanediol , 2,2-dimethyl-1,3-propanediol, 3-methyl-1,3-butanediol, 1,2-hexanediol, 2-ethyl-1,3-hexanediol, 3-methyl-1,5 -Pentanediol, 2-methylpentane-2,4-diol, trimethylolpropane, glycerin and the like. The liquid L may contain these moisturizing agents alone or may contain a plurality of them.

The content of the humectant in the liquid L is, for example, 1.0% by mass or more and 30.0% by mass or less, preferably 3.0% by mass or more and 20.0% by mass or less, and more preferably 5. 0
It is not less than mass% and not more than 16 mass %. When the content is 1.0% by mass or more and 30.0% by mass or less, it is possible to sufficiently suppress the clogging of the nozzle holes of the liquid application device 102.

The liquid L may contain water. Examples of water include deionized water, ultrafiltered water, reverse osmosis water, distilled water, and other pure water or ultrapure water. Water that has been sterilized by irradiation with ultraviolet rays or addition of hydrogen peroxide is preferable in that it can be stored for a long period of time by preventing the generation of mold and bacteria.

Other additives that can be contained in the liquid L include, for example, an ultraviolet absorber, a photo-stabilizer, a quencher, an antioxidant, a water-proofing agent, a fungicide, a preservative, a thickener, a fluidity improver, Examples thereof include pH adjusters, defoamers, foam suppressors, leveling agents and antistatic agents.

1.1.3. Features The fibrous body forming apparatus 100 has the following features, for example.

The fibrous body forming apparatus 100 includes a liquid application device 102 that applies a liquid L containing resin particles for binding a plurality of fibers to a web W2 including a plurality of fibers, and the surface tension of the liquid L is 20° C. It is 50 mN/m or less. Therefore, in the fibrous body molding apparatus 100, as shown in “3. Examples and Comparative Examples” to be described later, the liquid L penetrates into the web W2 as compared with the case where the surface tension at 20° C. is larger than 50 mN/m. It is possible to suppress the generation of paper dust. With this, when the sheet S is printed by the inkjet printer, it is possible to prevent the dot omission caused by the paper powder blocking the nozzle holes of the inkjet printer. In particular, since paper dust is likely to be generated when the sheet S is cut, it is preferable that the liquid L penetrates into the web W2.

Further, in the fibrous body forming apparatus 100, since the liquid L containing the resin particles for binding the plurality of fibers is applied to the web W2, the surface area per unit mass of the resin particles is large and the contact area between the fibers and the resin particles is large. Can be increased. Therefore, the binding force of the plurality of fibers can be increased, and the generation of paper dust can be suppressed. For example, when the resin particles for binding a plurality of fibers are supplied to the web as powder, the resin particles are aggregated, and it is difficult to increase the contact area between the fibers and the resin particles. Further, since the liquid L can enhance the binding force of the plurality of fibers, the amount of the resin particles can be reduced accordingly.

In the fibrous body molding apparatus 100, the average particle size of the resin particles contained in the liquid L is preferably 10 nm or more and 5 μm or less. Therefore, in the fibrous body molding apparatus 100, as shown in “3. Examples and Comparative Examples” to be described later, the liquid L reaches the inside of the web W2 as compared with the case where the average particle diameter of the resin particles is outside the above range. It can be permeated and the generation of paper dust can be suppressed. Furthermore, the stability of the viscosity of the liquid L can be improved.

In the fibrous body molding apparatus 100, the resin particles contained in the liquid L are a thermoplastic resin or a thermosetting resin. Therefore, in the fibrous body forming apparatus 100, the plurality of fibers contained in the web W2 can be bound by heating the web W2 coated with the liquid L.

In the fibrous body molding apparatus 100, the liquid L contains a penetrant. Therefore, in the fibrous body molding apparatus 100, the permeability of the liquid L can be improved.

In the fibrous body molding apparatus 100, the liquid L contains a moisturizer. Therefore, in the fibrous body forming apparatus 100, the liquid L can be easily discharged from the liquid applying apparatus 102.

The fibrous body forming apparatus 100 includes a pressurizing unit 82 that pressurizes the web W2 coated with the liquid L. Therefore, in the fibrous body molding apparatus 100, the bulk density of the web W2 can be increased by the pressing unit 82.

The fibrous body forming apparatus 100 includes a heating unit 84 that heats the web W2 to which the liquid L is applied. Therefore, in the fibrous body forming apparatus 100, the plurality of fibers included in the web W2 can be bound by heating the web W2 coated with the liquid L by the heating unit 84.

In the fibrous body molding apparatus 100, the liquid application device 102 is an inkjet head. Therefore, in the fibrous body forming apparatus 100, compared with the case where the liquid application device is a roller and the liquid is applied by the roller, the applied liquid L has better uniformity and the damage of the web W2 can be prevented. For example, when the liquid is applied by a roller, the web may stick to the roller, which may deteriorate the uniformity of the applied liquid L. Further, the web W2 may be damaged or the rollers may be contaminated, and cleaning of the rollers is required. The application with an inkjet head can avoid the above problems.

Further, in the fibrous body molding apparatus 100, the liquid L can be applied more efficiently than in the case where the liquid application device is a spray and the liquid is applied by spraying. In the case of spray application, there are many liquids that do not come into close contact with or penetrate the web even if the liquid is ejected from the spray. bad. Further, in the case of spray application, the web may be broken due to the pressure of the spray injection. The application with an inkjet head can avoid the above problems.

1.2. Fiber Body Forming Method Next, a fiber body forming method according to the first embodiment will be described with reference to the drawings. FIG. 3 is a flowchart for explaining the fibrous body molding method according to the first embodiment. In the fibrous body molding method according to the first embodiment, for example, fibers are molded using the fibrous body molding device 100.

First, as described in “1. Fiber body forming apparatus”, the web W2 including a plurality of fibers is prepared using the fiber body forming apparatus 100 (step S2).

Next, the liquid L containing the resin particles for binding the plurality of fibers is applied to the web W2 by the liquid applying device 102 (step S4). In this step, the liquid L is applied by an inkjet method.

Next, the pressing unit 82 presses the web W2 coated with the liquid L (step S6).

Next, the heating unit 84 heats the web W2 coated with the liquid L (step S8).

In addition to the above steps, the fiber body molding method according to the first embodiment may include the steps described in “1. Fiber body molding apparatus”.

1.3. Modified Example of Fibrous Body Forming Apparatus 1.3.1. First Modified Example Next, a fibrous body molding apparatus according to a first modified example of the first embodiment will be described with reference to the drawings. FIG. 4 is a diagram schematically showing a fibrous body molding device 110 according to a first modified example of the first embodiment.

Hereinafter, in the fibrous body molding apparatus 110 according to the first modified example of the first embodiment, differences from the example of the fibrous body molding apparatus 100 according to the first embodiment described above will be described, and description of the same points will be omitted. To do. This is the same in the fibrous body molding apparatuses according to the second and third modifications of the first embodiment shown below.

In the fibrous body forming apparatus 100 described above, as shown in FIG. 2, two liquid application devices 102 are provided, one liquid application device 102 is provided on one surface A1 side of the web W2, and the other liquid application device 102 is provided. The coating device 102 was provided on the other surface A2 side of the web W2.

On the other hand, in the fibrous body molding apparatus 110, as shown in FIG. 4, the liquid application device 102 is provided only on one surface A1 side of the web W2. In the fibrous body forming apparatus 110, the number of parts can be reduced as compared with the case where two liquid applying apparatuses 102 are provided. However, considering that the liquid L is surely permeated to the other surface A2 of the web W2, it is preferable to provide two liquid application devices 102 like the fibrous body molding device 100 described above.

1.3.2. Second Modified Example Next, a fibrous body molding apparatus according to a second modified example of the first embodiment will be described with reference to the drawings. FIG. 5: is a figure which shows typically the fiber body shaping|molding apparatus 120 which concerns on the 2nd modification of 1st Embodiment. It should be noted that FIG. 5 is a diagram viewed from the transport direction of the web W2.

In the fibrous body molding apparatus 100 described above, the liquid application apparatus 102 was an inkjet head.

On the other hand, in the fibrous body molding device 120, as shown in FIG. 5, the liquid application device 102 is a spray. The number of the liquid application devices 102 is not particularly limited, but in the illustrated example, four liquid application devices 102 are provided on one surface A1 side of the web W2 and four liquid application devices 102 are provided on the other surface A2 side of the web W2. Has been. On one surface A1 side, the four liquid application devices 102 are provided side by side in the width direction of the web W2, and on the other surface A2 side, the four liquid application devices 102 are provided side by side in the width direction of the web W2. Has been. Accordingly, the liquid L can be applied with good uniformity in the width direction of the web W2. The width direction of the web W2 is a direction orthogonal to the thickness direction of the web W2 and the transport direction of the web W2.

1.3.3. Third Modified Example Next, a fibrous body molding apparatus according to a third modified example of the first embodiment will be described with reference to the drawings. FIG. 6 is a diagram schematically showing a fibrous body molding device 130 according to a third modified example of the first embodiment.

As shown in FIG. 6, the fibrous body molding apparatus 130 is different from the fibrous body molding apparatus 100 described above in the arrangement of the liquid application device 102.

In the fibrous body forming apparatus 130, for example, one liquid application device 102 first applies the liquid L to one surface A1 of the web W2, and then the other liquid application device 102 applies the liquid L to the other surface of the web W2. The liquid L is applied to A2. The two liquid application devices 102 eject the liquid L toward the direction of gravity, for example. Therefore, the liquid L can be more reliably applied to the web W2.

For example, when at least one of the two liquid application devices 102 ejects the liquid L in the direction opposite to the direction of gravity, the action of gravity may prevent application of the liquid L to the web W2. is there.

In the illustrated example, the web W2 is transported in the first direction and the liquid L is applied to one surface A1 thereof, and then is transported in the gravity direction by the two transport rollers 132, and further in the direction opposite to the first direction. Is transported in the second horizontal direction and the liquid L is applied to the other surface A2. The first direction and the second direction are horizontal directions.

Note that, as shown in FIG. 7, the transport direction of the web W2 is the direction of gravity, and the two liquid application devices 102 may eject the liquid L toward the direction orthogonal to the direction of gravity. In this case, the two liquid application devices 102 may apply the liquid L to the web W2 at the same time.

2. Second embodiment 2.1. Fiber Body Forming Apparatus Next, a fiber body forming apparatus according to a second embodiment will be described with reference to the drawings. FIG. 8 is a diagram schematically showing the fibrous body molding device 200 according to the second embodiment.

Hereinafter, differences between the fibrous body molding apparatus 200 according to the second embodiment and the example of the fibrous body molding apparatus 100 according to the first embodiment described above will be described, and description of the same points will be omitted.

As shown in FIG. 8, the fibrous body molding apparatus 200 differs from the fibrous body molding apparatus 100 in that the fibrous body molding apparatus 200 includes a pressing unit 214.

The pressure unit 214 includes a pair of calender rollers 215, and presses the second web W2 by sandwiching it with a predetermined nip pressure. The web W2 is pressed by the pressing portion 214, so that the thickness of the web W2 is reduced and the bulkiness of the web W2 is increased. One of the pair of calendar rollers 215 is a driving roller driven by a motor (not shown), and the other is a driven roller.

The pressurizing unit 214 pressurizes the web W2 so that the bulk density of the web W2 is, for example, 0.09 g/cm ³ or more, preferably 0.09 g/cm ³ or more and 0.80 g/cm ³ or less, and more preferably Is 0.40 g/cm ³ or more and 0.60 g/cm ³ or less. In addition, "bulk density" means loose bulk density.

Pressure pressing 214 applies to the web W2 is, for example, 1 kgf / cm ² or more 600 kgf / cm ² or less, preferably 1 kgf / cm ² or more 500 kgf / cm ² or less, more preferably 3 kgf / cm ² or more It is 300 kgf/cm ² or less.

The liquid application device 102 applies the liquid L to the web W2 pressed by the pressing unit 214. The liquid application device 102 is provided, for example, between the calender roller 215 of the pressing unit 214 and the calender roller 85 of the pressing unit 82. The diameter of the calendar roller 85 is smaller than the diameter of the calendar roller 215. Therefore, the pressing unit 82 can press the web W2 with a force larger than that of the pressing unit 214. Furthermore, since the diameter of the calender roller becomes smaller as the web W2 is conveyed, it is possible to prevent the calender rollers 85 and 215 from slipping with respect to the web W2.

The fibrous body forming apparatus 200 has the following features, for example.

In the fibrous body forming apparatus 200, the liquid application device 102 applies the liquid L to the web W2 having a bulk density of 0.09 g/cm ³ or more. Therefore, in the fibrous body molding apparatus 200, the voids of the web W2 are smaller than in the case where the liquid is applied to the web having a bulk density of less than 0.09 g/cm ³ , and the capillary phenomenon is generated when the liquid L permeates the web W2. Is easily expressed. This allows the liquid L to penetrate into the web W2.

In the fibrous body forming apparatus 200, the liquid application device 102 applies the liquid L to the web W2 having a bulk density of 0.80 g/cm ³ or less. Therefore, in the fibrous body molding apparatus 100, it is possible to prevent the bulk density from being too high and the capillarity phenomenon to be difficult to develop.

The fibrous body forming apparatus 100 includes a pressurizing unit 82 that pressurizes the web W2 coated with the liquid L. Therefore, in the fibrous body forming apparatus 100, the permeability of the liquid L into the web W2 can be further increased.

For example, the web W2 pressed by the pressing unit 214 has a phenomenon called springback in which the bulk density is slightly lowered due to the springiness of the fibers. Further, the web W2 coated with the liquid L has a slightly lower bulk density due to the swelling of the fibers. Therefore, the capillary phenomenon is unlikely to occur, and the permeability of the liquid L into the web W2 may decrease.

In the fibrous body forming apparatus 200, even if the bulk density of the web W2 is reduced due to springback and swelling of the fibers, the bulk density can be recovered by the pressing unit 82. Therefore, the permeability of the liquid L into the web W2 can be further increased.

2.2. Fiber Body Forming Method Next, a fiber body forming method according to the second embodiment will be described with reference to the drawings. FIG. 9 is a flowchart for explaining the fibrous body molding method according to the second embodiment. In the fibrous body molding method according to the second embodiment, for example, fibers are molded using the fibrous body molding device 200.

First, the web W2 including a plurality of fibers is prepared using the fibrous body molding device 200 (step S2).

Next, the web W2 is pressed by the pressing unit 214. By this step, the bulk density of the web W2 is set to, for example, 0.09 g/cm ³ or more and 0.80 g/cm ³ or less.

Next, the liquid L containing the resin particles for binding the plurality of fibers is applied to the pressurized web W2 by the liquid applying device 102 (step S4). In this step, the liquid L is applied to the web W2 having a bulk density of, for example, 0.09 g/cm ³ or more and 0.80 g/cm ³ or less.

Next, the pressing unit 82 presses the web W2 coated with the liquid L (step S6).

Next, the heating unit 84 heats the web W2 coated with the liquid L (step S8).

In addition to the above steps, the fiber body molding method according to the second embodiment may include the steps described in “1. Fiber body molding apparatus”.

2.3. Modified Example Next, a fibrous body molding apparatus according to a modified example of the second embodiment will be described with reference to the drawings. FIG. 10: is a figure which shows typically the fibrous body shaping|molding apparatus 220 which concerns on the modification of 2nd Embodiment.

Hereinafter, in the fibrous body molding device 220 according to the modified example of the second embodiment, differences from the example of the fibrous body molding device 200 according to the second embodiment described above will be described, and description of the same points will be omitted.

As shown in FIG. 10, the fibrous body molding apparatus 220 differs from the fibrous body molding apparatus 100 described above in that the fibrous body molding apparatus 220 includes pressurizing units 222 and 224 that press the web W2.

The pressure unit 222 presses the web W2 pressed by the pressure unit 214. The pressing unit 224 presses the web W2 pressed by the pressing unit 222. The liquid application device 102 applies the liquid L to the web W2 pressed by the pressing unit 224.

The pressurizing unit 222 includes a pair of calender rollers 223, and presses the web W2 with a predetermined nip pressure. The web W2 is pressed by the pressurizing section 222, so that the thickness of the web W2 is reduced and the bulkiness of the web W2 is increased. One of the pair of calender rollers 223 is a driving roller driven by a motor (not shown), and the other is a driven roller.

The pressure unit 224 includes a pair of calender rollers 225, and presses the web W2 by sandwiching the web W2 with a predetermined nip pressure. The web W2 is pressed by the pressing unit 224, so that the thickness of the web W2 is reduced and the bulkiness of the web W2 is increased. One of the pair of calender rollers 225 is a driving roller driven by a motor (not shown), and the other is a driven roller.

The diameter of the calendar roller 223 is smaller than the diameter of the calendar roller 215. Therefore, the pressing unit 222 can press the web W2 with a force larger than that of the pressing unit 214. The diameter of the calendar roller 225 is smaller than the diameter of the calendar roller 223. Therefore, the pressing unit 224 can press the web W2 with a force larger than that of the pressing unit 222. Furthermore, since the diameter of the calender roller becomes smaller as it goes in the transport direction of the web W2, it is possible to prevent the calender rollers 215, 223, 225 from slipping with respect to the web W2.

In the illustrated example, the fibrous body molding device 220 has four pressurizing units 82, 214, 222, 224, but the number thereof is not particularly limited. For example, the fibrous body forming device 220 may not have the pressing unit 224, and may have five or more pressing units.

3. Examples and Comparative Examples The present invention will be described more specifically by showing Examples and Comparative Examples below. The present invention is not limited to the following examples and comparative examples.

A sheet was molded using a fibrous body molding device corresponding to the fibrous body molding device 100 shown in FIGS. 1 and 2. The liquids L1 to L5 were applied to both sides of the web by using an inkjet head as a liquid application device. The coating amount of the liquids L1 to L5 was 8 g/m ^{2 on} one side of the web, and the total coating amount on both sides of the web was 16 g/m ² . The temperature of the heating part was set to 150°C. As the raw material, recycled paper “G80” (manufactured by Mitsubishi Paper Mills) was used.

FIG. 11 is a table showing compositions of the liquids L1 to L5. The unit of the numbers in the table is% by mass. Water was added as the remaining amount to make 100% by mass in total. In the table, “PU” is polyurethane and was manufactured by the following method.

In a reaction vessel equipped with a stirrer, a reflux condenser and a thermometer, 1500 g of a polycarbonate diol having a molecular weight of 3000, 320 g of 2,2-dimethylolpropionic acid (DMPA), and 1347 g of 2-pyrrolidone of bp (boiling point) 245° C. It was charged under a nitrogen stream and heated to 60° C. to dissolve DMPA. 1,245 g of 4,4′-dicyclohexylmethane diisocyanate and 2.6 g of “Urethane Catalyst XK-614” manufactured by Kusumoto Kasei Co., Ltd. were added, and the mixture was heated to 90° C. and subjected to a urethane reaction for 5 hours to obtain a urethane prepolymer. It was

Next, the reaction mixture was cooled to 80° C., 220 g of triethanolamine was added and mixed, and 4340 g was taken out and added to a mixed solution of 5400 g of water and 22 g of triethanolamine under strong stirring. It was Next, 1500 g of ice was added, 42 g of a 35% aqueous solution of 2-methyl-1,5-pentanediamine was added to carry out a chain extension reaction, and the solvent was distilled off so that the solid content concentration became 30%. An aqueous dispersion of particles was obtained. Further, by adjusting the reaction, aqueous dispersions of urethane resin particles having different average particle diameters were obtained.

Polyurethane was produced by the above method.

Further, in the table of FIG. 11, “AC” is a styrene acrylic acid copolymer, and “John Krill 61” manufactured by BASF Corporation was used. “SB” is a styrene-butadiene copolymer, and “2507H” manufactured by Nippon Zeon Co., Ltd. was used. “E1010” is Olfin E1010 manufactured by Nissin Chemical Co., Ltd. "TEGmBE" is triethylene glycol monobutyl ether and "Gly" is glycerin.

The surface tension of the liquids L1 to L5 adjusted to 20° C. was measured using a surface tension meter “DY-500” manufactured by Kyowa Interface Science Co., Ltd.

Moreover, the average particle diameter of the resin particles contained in the liquids L1 to L5 was measured using a particle size distribution meter “Microtrac UPA-150” manufactured by Nikkiso Co., Ltd.

In addition, pressure was applied to the web before the liquids L1 to L5 were applied. By changing the pressure, the bulk density of the web before the liquids L1 to L5 were applied was changed. The bulk density of the web was calculated by the following formula based on the method described in "JIS P 8118".

Bulk density (g/cm ³ )=grammage (g/cm ² )/thickness (nm)×1000

Continuous printability and liquid stability were evaluated for the evaluation samples as described above.

Regarding the continuous printability, 40 sheets of the prepared sample were continuously printed by an inkjet printer “PXS160T” manufactured by Seiko Epson Corporation to evaluate dot dropout. The evaluation criteria are as follows.

A: No dot omission occurred even after 30 or more sheets.
B: Dot omission occurred on 20 or more and less than 30 sheets.
C: Dot omission occurred on 10 or more and less than 20 sheets.
D: Dot omission occurred in less than 10 sheets.

The liquid stability was determined by measuring the viscosity before and after storage after storing 50 g of the liquids L1 to L5 in a glass bottle in an airtight manner and storing the liquid at 60° C. for 1 week. , And evaluated as liquid stability. The viscosity was measured using a vibration type viscometer "VM100A" manufactured by Seconic. The evaluation criteria are as follows.

A: The rate of change in viscosity was less than 10%.
B: The rate of change in viscosity was 10% or more and less than 20%.
C: The rate of change in viscosity was 20% or more.

FIG. 12 is a table showing evaluation results of continuous printability and liquid stability of Examples 1 to 14 and Comparative Example 1.

As shown in FIG. 12, Examples 1 to 14 had better continuous printability than Comparative Example 1. This is because Examples 1 to 12 have a surface tension of 50 mN/m or less and the surface tension of the liquids L1 to L5 is smaller than that of Comparative Example 1, so that the liquids L1 to L5 penetrate into the inside of the web. This is because paper dust is less likely to be generated and the possibility that paper powder may block the nozzle holes of the inkjet printer when printing with the inkjet printer.

Further, in Examples 1 to 6, the continuous printability was better than that in Example 7. This is because in Examples 1 to 6, the average particle size of the resin particles is 5 μm or less, which is smaller than that in Example 7, so that the surface area per unit mass of the resin particles is large and the contact area between the fibers and the resin particles is large. Is large. Also, by comparing Examples 9 and 10, it was found that the liquid stability can be improved by setting the average particle size of the resin particles to 10 μm or more.

Further, Examples 9 to 11 had better continuous printability than Example 8. This is because the bulk density of Examples 9 to 11 was 0.09 g/cm ³ or more, and thus the capillary phenomenon was more likely to occur than in Example 8, and the liquid L1 penetrated into the inside of the web. In addition, since the bulk density of Example 12 is too large, the capillary phenomenon is less likely to occur than in the case of Example 11, and the liquid L1 is less likely to penetrate into the inside of the web. It is considered that the printability evaluation result was poor.

The present invention may omit some of the configurations or combine the embodiments and modifications within the scope of the features and effects described in the present application.

The present invention is not limited to the above-described embodiment, and various modifications can be made. For example, the invention includes configurations that are substantially the same as the configurations described in the embodiments. The substantially same structure is, for example, a structure having the same function, method, and result, or a structure having the same object and effect. Further, the invention includes configurations in which non-essential parts of the configurations described in the embodiments are replaced. Further, the invention includes a configuration that achieves the same effect as the configuration described in the embodiment or a configuration that can achieve the same object. Further, the invention includes configurations in which known techniques are added to the configurations described in the embodiments.

2, 3, 7, 8... Tube, 8... Tube, 9... Shoot, 10... Supply section, 12... Coarse crushing section, 14... Coarse crushing blade, 20... Disentanglement section, 22... Inlet port, 23... Tube, 24... Discharge port, 26... Disentanglement blower, 27... Dust collection part, 28... Collection blower, 29... Pipe, 40... Sorting part, 41... Drum part, 42... Inlet port, 43... Housing part, 44... Discharge Outlet, 45... First web forming section, 46... Mesh belt, 47... Roller, 48... Suction section, 49... Rotating body, 54... Tube, 56... Blower, 60... Accumulation section, 61... Drum section, 62... Introduction Mouth, 63... Housing part, 70... Second web forming part, 72... Mesh belt, 74... Roller, 76... Suction mechanism, 77... Suction blower, 79... Conveying part, 79a... Mesh belt, 79b... Roller, 79c... Suction mechanism, 80... Sheet forming section, 82... Pressing section, 84... Heating section, 85... Calendar roller, 86... Heating roller, 90... Cutting section, 92... First cutting section, 94... Second cutting section, 96 ... discharge part, 100... fibrous body molding device, 102... liquid application device, 110, 120, 130... fibrous body molding device, 132... conveyance roller, 200... fibrous body molding device, 202, 204, 206, 208, 210, 212... Humidifying part, 214... Pressing part, 215... Calender roller, 220... Fibrous body molding device, 222... Pressing part, 223... Calender roller, 224... Pressing part, 225... Calender roller

Claims (11)

A step of applying a liquid containing resin particles for binding the plurality of fibers to a web containing a plurality of fibers,
The fibrous body molding method, wherein the surface tension of the liquid at 20° C. is 50 mN/m or less. In claim 1,
The fibrous body molding method, wherein the resin particles have an average particle diameter of 10 nm or more and 5 μm or less. In claim 1 or 2,
The fibrous body molding method, wherein the resin particles are a thermoplastic resin or a thermosetting resin. In any one of Claim 1 thru|or 3,
A method for molding a fibrous body, wherein the liquid contains a penetrant. In any one of Claim 1 thru|or 4,
The said liquid contains a moisturizing agent, The fibrous body shaping|molding method. In any one of Claim 1 thru|or 5,
In the step of applying the liquid,
A fibrous body molding method, wherein the liquid is applied to the web having a bulk density of 0.09 g/cm ³ or more. In claim 6,
In the step of applying the liquid,
A fibrous body molding method, wherein the liquid is applied to the web having a bulk density of 0.80 g/cm ³ or less. In any one of Claims 1 thru|or 7,
A method for molding a fibrous body, comprising the step of pressurizing the web coated with the liquid. In any one of Claim 1 thru|or 8,
A method for molding a fibrous body, comprising the step of heating the web coated with the liquid. In any one of Claim 1 thru|or 9,
In the step of applying the liquid,
A fibrous body molding method, wherein the liquid is applied by an inkjet method. A web containing a plurality of fibers, including a liquid application device for applying a liquid containing resin particles for binding the plurality of fibers,
The fibrous body molding apparatus, wherein the surface tension of the liquid is 50 mN/m or less at 20°C.

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